Power tailgate motor mount cartridge assembly

A power tailgate assembly for a vehicle includes a tailgate configured to rotatably couple to the vehicle, the tailgate having an inner panel, an outer panel, a bottom panel, and first and second side panels defining an inner cavity. An opening is defined in at least one of the first side panel and the bottom panel, and a motor mount cartridge assembly is disposed in the inner cavity at least partially within the opening to at least partially conceal the motor mount cartridge assembly within the tailgate. When installed, the motor mount cartridge assembly covers the opening without need for a discrete cover for the opening.

FIELD

The present application relates generally to vehicle tailgates and, more particularly, to a motor mount cartridge assembly for a power tailgate.

BACKGROUND

Some vehicles such as pickup trucks include cargo areas accessible by a tailgate. Some tailgates can be automatically opened and closed via one or more motors. Conventional powered tailgates have to this point required a motor installation opening that requires a close-off cover, which can result in unbalanced loads and undesirable appearances, as well as additional cost and complexity associated with manufacturing the vehicle. While such conventional power tailgates work well for their intended purpose, there remains a need for improvement in the relevant art.

SUMMARY

In one example aspect of the invention, a power tailgate assembly for a vehicle is provided. In one example embodiment, the assembly includes a tailgate configured to rotatably couple to the vehicle, the tailgate having an inner panel, an outer panel, a bottom panel, and first and second side panels defining an inner cavity, an opening defined in at least one of the first side panel and the bottom panel, and a motor mount cartridge assembly disposed in the inner cavity at least partially within the opening to at least partially conceal the motor mount cartridge assembly within the tailgate. When installed, the motor mount cartridge assembly covers the opening without need for a discrete cover for the opening.

In addition to the foregoing, the described power tailgate assembly may include one or more of the following features: wherein the motor mount cartridge assembly is coupled to the inner panel and the first side panel, the motor mount cartridge assembly including a bottom wall such that the motor mount cartridge assembly automatically covers the opening with the bottom wall when installed to the tailgate; wherein the motor mount cartridge assembly includes a pivot cup configured to receive a post extending from the vehicle to rotatably couple the tailgate to the vehicle.

In addition to the foregoing, the described power tailgate assembly may include one or more of the following features: wherein the motor mount cartridge assembly comprises a motor assembly coupled to a cartridge body; wherein the cartridge body includes a bottom wall, a side wall, and a front wall; wherein the motor assembly is coupled to the front wall and the bottom wall; and wherein the cartridge body includes a plurality of locating and retaining tabs extending from the front wall.

In addition to the foregoing, the described power tailgate assembly may include one or more of the following features: wherein the cartridge body includes an integrally formed pivot cup configured to receive a post extending from the vehicle to rotatably couple the tailgate to the vehicle; wherein the motor assembly comprises a motor, a driveshaft, and an electrical connector; and wherein the motor mount cartridge assembly is installed in the inner cavity between the tailgate inner and outer panels such that an uninterrupted surface is maintained of the inner and outer panels.

In another aspect of the invention, a vehicle is provided. In one example embodiment, the vehicle includes a power tailgate assembly comprising a tailgate rotatably coupled to the vehicle, the tailgate having an inner panel, an outer panel, a bottom panel, and first and second side panels defining an inner cavity, an opening defined in at least one of the first side panel and the bottom panel, and a motor mount cartridge assembly disposed in the inner cavity at least partially within the opening to at least partially conceal the motor mount cartridge assembly within the tailgate. When installed, the motor mount cartridge assembly covers the opening without need for a discrete cover for the opening.

In addition to the foregoing, the described vehicle may include one or more of the following features: wherein the vehicle is a pickup truck with a truck bed defined at least partially by the tailgate; wherein the motor mount cartridge assembly is coupled to the inner panel and the first side panel, the motor mount cartridge assembly including a bottom wall such that the motor mount cartridge assembly automatically covers the opening with the bottom wall when installed to the tailgate; and wherein the motor mount cartridge assembly includes a pivot cup configured to receive a post extending from the vehicle to rotatably couple the tailgate to the vehicle.

In addition to the foregoing, the described vehicle may include one or more of the following features: wherein the motor mount cartridge assembly comprises a motor assembly coupled to a cartridge body; wherein the cartridge body includes a bottom wall, a side wall, and a front wall; wherein the motor assembly is coupled to the front wall and the bottom wall; wherein the cartridge body includes an integrally formed pivot cup configured to receive a post extending from the vehicle to rotatably couple the tailgate to the vehicle; and wherein the motor assembly comprises a motor, a driveshaft, and an electrical connector.

DESCRIPTION

According to the principles of the present disclosure, a concealed drive unit for a powered pickup tailgate is presented. The drive unit powers the tailgate up and down without assistance by the user. A bottom of the tailgate includes an opening between inner and outer panels that is configured to receive a cartridge assembly, which includes the drive unit (e.g., motor assembly) mounted onto a structural cartridge. The cartridge assembly quickly and easily installs vertically into the opening and is substantially concealed within the tailgate cavity between the inner and outer panels. The cartridge includes an integrated pivot cup to enable pivotal coupling with a post on the vehicle. A bottom surface of the cartridge assembly automatically closes out the opening when installed in the tailgate.

Referring now toFIG. 1, a rear perspective view of a vehicle10is illustrated. The vehicle10has a storage bed12located above one or more rear wheels14. In one exemplary implementation, the vehicle10is a pickup truck as illustrated. In another exemplary implementation, the vehicle10is a vehicle having a cargo area above the rear wheel(s)14and a closure member, such as a sport utility vehicle with a rear cargo area and a rear hatch. The storage bed12has a cargo area16having a floor18, sidewalls20, and a tailgate22that is shown in a closed position.

Referring now toFIGS. 2-4, an example power tailgate assembly30for vehicle10is illustrated. In the example embodiment, power tailgate assembly30generally includes tailgate22and a motor mount cartridge assembly32. As described herein in more detail, the cartridge assembly32is configured to be inserted into the tailgate22to provide power opening/closing thereof.FIG. 2illustrates power tailgate assembly30before cartridge assembly32is mounted to the tailgate22, andFIGS. 3 and 4illustrate the power tailgate assembly30after cartridge assembly32is mounted to the tailgate22.

With continued reference toFIG. 2, the tailgate22generally includes an inner panel40, an outer panel42, a top panel44, a bottom panel46, and opposed side panels48,50. A tailgate inner cavity52is generally defined by the panels of the tailgate22. A first side54(e.g., driver side) of the tailgate22includes side panel50, which further includes a pivot cup56configured to receive a post58coupled to or formed in the vehicle main body (e.g., sidewall20). The pivot cup56and post58are operably connected to rotatably couple the tailgate first side54to the vehicle10.

In the example embodiment, a second side60of the tailgate22includes an opening62defined in the bottom panel46and the side panel48. As shown inFIGS. 3 and 4, the cartridge assembly32is configured to be inserted into the opening62and into the tailgate inner cavity52between the inner and outer panels40,42such that the cartridge assembly32is substantially concealed within the tailgate22and covers opening62.

As described herein in more detail, the cartridge assembly32includes a bottom surface configured to close off the opening when the cartridge assembly32is in an installed position, which eliminates the need for a separate close-out panel. As also described herein in more detail, the cartridge assembly32defines a pivot cup64configured to receive a post66coupled to or formed in the vehicle main body (e.g., sidewall20). The pivot cup64and post66are operably connected to rotatably couple the tailgate second side60to the vehicle10.

Because cartridge assembly32is inserted into the bottom panel46, a cover is not required on the inner or outer panels40,42to close off the cartridge assembly32. As such, in the tailgate closed position, cartridge assembly32is not visible or is minimally visible. In the tailgate open position, only a small portion of the cartridge assembly32is visible through the bottom panel opening62. As such, an uninterrupted class ‘A’ surface can be maintained on the inner and outer panels40,42.

Referring now toFIGS. 5 and 6, the motor mount cartridge assembly32will be described in more detail. In the example embodiment, cartridge assembly32generally includes a structural cartridge body70and a motor assembly72.

In the example embodiment, the structural cartridge body70generally includes a front wall74, a bottom panel or wall76, and a side wall78. The front wall74includes a pair of locating and retaining tabs80extending upwardly therefrom, and a pair of fastener apertures82. The locating and retaining tabs80are configured to facilitate locating the cartridge assembly32within the tailgate inner cavity52in a proper/desired orientation when inserted into the bottom panel opening62. The fastener apertures82are configured to receive fasteners84(FIG. 5) for coupling the motor assembly72to the cartridge body70. The front wall74also includes a plurality of second fastener apertures86configured to receive fasteners88, which are inserted through fastener apertures90(FIG. 2) formed in the inner panel40(seeFIG. 4), to thereby couple the cartridge assembly32to the tailgate22.

In the illustrated example, cartridge body bottom wall76includes a first set of fastener apertures92and a second set of fastener apertures94. The first set of fastener apertures92are configured to receive fasteners96(FIG. 4) for further coupling the motor assembly72to the cartridge body70. The second set of fastener apertures94are configured to receive fasteners98(FIGS. 4 and 6) for coupling the cartridge body70to the tailgate bottom panel46, as shown inFIG. 4.

In the example embodiment, the cartridge body side wall78includes the pivot cup64, a first set of fastener apertures100, and a second fastener aperture102. The pivot cup64is integrally formed in the cartridge body70so as to protect the motor assembly72(e.g., drive unit and shaft coupling) during tailgate installation and removal. In one example, the pivot cup64includes an opening104configured to enable installation and removal of tailgate22at 45° or approximately 45°, and facilitates stabilizing and retaining the tailgate22when in the fully open and closed positions. The first set of apertures100are configured to receive fasteners106(FIG. 4), which are inserted through fastener apertures108(FIG. 2) formed in the side panel48, to thereby further couple the cartridge assembly32to the tailgate22(seeFIG. 4). The second fastener aperture102is configured to receive a fastener110for coupling the cartridge body70to the tailgate side panel48, as shown inFIG. 4.

As briefly described above, when the cartridge assembly32is installed in the inner cavity52via opening62, the bottom wall76automatically aligns with and covers the opening62. In one example implementation, when the cartridge assembly32is installed, the bottom wall76is disposed flush with or substantially flush with the tailgate bottom panel46. In one example implementation, when the cartridge assembly32is installed, the side wall78is disposed flush with or substantially flush with the tailgate side panel48.

As shown inFIG. 6, in the example embodiment, motor assembly72generally includes a motor120, a driveshaft122, and an electrical connector124. The electrical connector124is configured to couple to a controller126(e.g., ECU) to power and selectively control the motor120. The controller126is configured to communicate with a user activation device (e.g., a key fob) and tailgate latches (not shown) for power opening/closing of the tailgate22. The motor120is configured to rotate the driveshaft122. In the example embodiment, the distal end of the driveshaft122includes a drive coupling128, which is rotatably disposed within the pivot cup64. The drive coupling128is sized and shaped to receive and operably connect to the post66. As the motor rotates the driveshaft122and the drive coupling128, the tailgate is rotated opened or closed depending on direction of rotation. In addition, the motor120includes electronics for obstruction detection to facilitate protecting the motor.

Described herein are systems and methods for a motor mount cartridge assembly that is quickly and easily installed into a power tailgate and substantially concealed therein. The cartridge assembly can be installed into the tailgate cavity after the paint operation through an opening at a bottom corner of the tailgate between the inner and outer panels. The cartridge assembly is mounted to the tailgate inner panel front face and side face. A motor assembly is pre-assembled onto the cartridge body, which includes an integrally formed pivot cup. Accordingly, the systems provide an aesthetically pleasing appearance of the tailgate inner panel without any added cover to the class ‘A’ styled reinforcing pattern of the tailgate inner panel. Additionally, the cartridge assembly enables a lower cross-car reinforcement to continue across the tailgate without being truncated.

It will be understood that the mixing and matching of features, elements, methodologies, systems and/or functions between various examples may be expressly contemplated herein so that one skilled in the art will appreciate from the present teachings that features, elements, systems and/or functions of one example may be incorporated into another example as appropriate, unless described otherwise above. It will also be understood that the description, including disclosed examples and drawings, is merely exemplary in nature intended for purposes of illustration only and is not intended to limit the scope of the present disclosure, its application or uses. Thus, variations that do not depart from the gist of the present disclosure are intended to be within the scope of the present disclosure.