Abstract:
A tailgate structural configuration accommodates the housing of a supplemental tailgate internally within the tailgate. The tailgate is formed with an outer panel and an inner panel to define an internal cavity. The upper portion of the tailgate includes a C-channel frame member connected to both the inner and outer panels to support guide tubes telescopically housing the supplemental tailgate. To enhance structural stability, the tailgate further includes one or two transversely oriented strainers having formed therein flanged depressions or openings for the passage of the guide tubes vertically therethrough. Each guide tube is affixed to a mounting bracket that is detachably connected to the C- channel to support the guide tube within the tailgate. Positioning pins mounted on the mounting bracket affixed to the guide tubes engage locator holes in the C-channel for positioning the supplemental tailgate.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application claims domestic priority on U.S. Provisional Patent Application Ser. No. 60/743,277, filed on Feb. 10, 2006, and entitled “Modified Tailgate to House a Supplemental Tailgate”, the contents of which are incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION  
       [0002]     This invention relates to the utilization of a supplemental tailgate apparatus housed with the tailgate of a pick-up truck and, more particularly, to structural modifications made to the tailgate assembly to receive a supplemental tailgate apparatus for deployment therefrom.  
       BACKGROUND OF THE INVENTION  
       [0003]     Conventionally, pickup trucks include a tailgate at the back of a bed that closes off a cargo box. Often times, the truck bed is not long enough to hold the cargo, so truck bed extenders have been developed. The truck bed extenders work in conjunction with the open tailgate in order to provide additional length to the bed. Some of the bed extenders mount to the outside of the tailgate or to the box itself, which may be convenient for deployment, but they tend to interfere with cargo space in the box since the bed extender, when not in use, protrudes into the box. Moreover, it is typical for the vehicle operator to employ the extender only occasionally, so it is generally undesirable to have the extender exposed at all times, which detracts from the attractiveness of the vehicle.  
         [0004]     Additionally, it is sometimes desirable to have an extender that can provide other functions in addition to a bed extender, such as a box extender function—an upwardly extending structure from the rearmost edge of an open tailgate that mimics the function of a closed tailgate. Such arrangements are particularly useful for carrying a load that is longer than the bed, but needs rearward support, such as provided by a closed tailgate, in order to prevent the load from falling rearwardly off the pick-up truck. Again, though, typical box extenders that provide adequate functionality are externally mounted and not only detract from the vehicle appearance when not in use but also require changes to the box for mounting such extenders. Also, most of these types of extenders are very cumbersome to deploy and later stow away, thus being undesirable for the operator to use. Such functions may be provided with simple ergonomic operation of the assembly, while still allowing for an attractive appearance for the vehicle when the extender is stowed during periods of non-use. Thus, while the exterior mounted extenders may be able to perform multiple functions, they still suffer from the drawbacks of an unattractive appearance and taking up room in the bed even when not in use.  
         [0005]     Positioning the extended supplemental tailgate structure generally perpendicularly to the plane of the main tailgate structure, while the main tailgate structure is moved to an open position such that the plane of the tailgate structure is substantially parallel to the bed of the pickup truck, places the extended supplemental tailgate structure in an orientation that is substantially parallel to the main tailgate structure when the main tailgate structure is in a normal closed position. In such an extended position, the supplemental tailgate can provide a restriction to the rearward movement of objects located on the bed of the pickup truck. Furthermore, such an extended position of the supplemental tailgate can provide support for objects placed on top of the supplemental tailgate.  
         [0006]     Positioning the extended supplemental tailgate structure such that the supplemental tailgate structure hangs below the plane of the main tailgate structure permits the cross member of the supplemental tailgate to be utilized as a step. In fact, U.S. Pat. No. 6,918,624, granted on Jul. 19, 2005, teaches that the cross member of the supplemental tailgate apparatus can incorporate a flip-out step that enlarges the surface of the underside of the cross member of the supplemental tailgate structure to enhance the use thereof as a step. Such utilization of the supplemental tailgate apparatus assists the operator in gaining physical access to the cargo area of the pick-up truck, which is particularly helpful whenever the bed of the pick-up truck to positioned substantially above the ground surface.  
         [0007]     Such a supplemental tailgate apparatus is preferably housed within the interior of the main tailgate structure so that the supplemental tailgate apparatus is retracted into the interior of the main tailgate when not being utilized as either a step and/or as a cargo area extension device, and, as a result, the main tailgate with a retracted supplemental tailgate apparatus looks substantially the same as a conventional tailgate assembly. The conventional main tailgate assembly, however, because of internal structural members and the configuration of the conventional main tailgate assembly, cannot receive the movable supplemental tailgate apparatus without undergoing some structural modifications.  
         [0008]     Accordingly, it would be desirable to provide a main tailgate assembly on a pick-up truck that would be capable of receiving a supplemental tailgate apparatus in a manner to allow the operation of the supplemental tailgate apparatus in the various desired functions.  
       SUMMARY OF THE INVENTION  
       [0009]     It is an object of this invention to overcome the aforementioned disadvantages of the known prior art by providing structural modifications within the main tailgate structure to permit the mounting of a supplemental tailgate apparatus internally of the main tailgate assembly on a pick-up truck.  
         [0010]     It is a feature of this invention that the main tailgate structure is provided with a C-channel member or reinforcement member positioned at the top or near the top of the main tailgate assembly to be engaged by the inner and outer tailgate panels and provide structural support at the top of the main tailgate assembly for the mounting of a supplemental tailgate apparatus.  
         [0011]     It is an advantage of this invention that the C-channel member or reinforcement member may have a pair of upright legs that support, respectively, the inner and outer main tailgate panels.  
         [0012]     It is another advantage of this invention that the upright legs of the C-channel member or reinforcement member are capable of engagement with the inner and outer panels of the main tailgate structure through welding, riveting or a hemming process.  
         [0013]     It is still another feature of this invention that the C-channel or reinforcement member may include a horizontal web member oriented orthogonally to the upright legs to permit the mounting of the supplemental tailgate apparatus and increase section modulus.  
         [0014]     It is another feature of this invention that the main tailgate assembly has at least one internal transverse reinforcement member spanning between and supporting the inner and outer panels of the main tailgate assembly.  
         [0015]     It is still another feature of this invention that each internal transverse support member is formed with a depression notch to permit a guide tube or the like to pass through the internal transverse support member.  
         [0016]     It is yet another advantage of this invention that the guide tubes or the like that receive the supplemental tailgate structure are detachably mounted by fasteners or the like to the main tailgate structure at both the top and the bottom of the respective guide member.  
         [0017]     It is yet another feature of this invention that each guide tube or the like is affixed to a mounting bracket at the top of the guide tube to permit the detachable connection thereof to the C-channel member or reinforcement member at the top of the main tailgate assembly.  
         [0018]     It is still another advantage of this invention that a mounting bracket for supporting a grab handle mechanism may be incorporated into the internal modifications around a guide tube to provide support for the deployment of a grab handle to be utilized in conjunction with deployment of the supplemental tailgate apparatus when being utilized as a step function.  
         [0019]     It is a further advantage of this invention that the mounting bracket for detachably connecting the guide tube to the C-channel can be welded directly to the guide tube.  
         [0020]     It is another object of this invention to provide a main tailgate assembly that will permit the receipt of and deployment of a supplemental tailgate apparatus from the interior of a main tailgate assembly while maintaining the conventional appearance of the main tailgate assembly for a pick-up truck.  
         [0021]     It is still another object of this invention to support in a rigid manner a supplemental tailgate apparatus within the interior of a main tailgate assembly without incurring rattles resulting from an interfering supplemental tailgate apparatus.  
         [0022]     It is a further object of this invention to provide a main tailgate assembly for use with a supplemental tailgate apparatus that is durable in construction, inexpensive of manufacture, carefree of maintenance, facile in assemblage, and simple and effective in use.  
         [0023]     These and other objects, features and advantages are accomplished according to the instant invention by providing a tailgate structural configuration that accommodates the housing of a supplemental tailgate internally within the tailgate. The tailgate is formed with an outer panel and an inner panel to define an internal cavity. The upper portion of the tailgate includes a C-channel frame member or the like, such as a reinforcement member, connected to both the inner and outer panels to support guide tubes housed in the supplemental tailgate. To enhance structural stability, the tailgate further includes one or two transversely oriented strainers having formed therein flanged depressions or openings for the passage of the guide tubes vertically therethrough. Each guide tube is affixed to a mounting bracket that is detachably connected to the C-channel member or reinforcement member to support the guide tube within the tailgate. Positioning pins mounted on the mounting bracket affixed to the guide tube engage locator holes in the C-channel for positioning the supplemental tailgate.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0024]     The advantages of this invention will become apparent upon consideration of the following detailed disclosure of the invention, especially when taken in conjunction with the accompanying drawings wherein:  
         [0025]      FIG. 1  is a perspective view of a tailgate for the cargo bed of a pick-up truck incorporating the principles of the instant invention, the extendable supplemental tailgate apparatus being shown in phantom elevated above the tailgate assembly;  
         [0026]      FIG. 2  is an elevational view of the tailgate assembly looking from the aspect of the outer panel with the outer panel being removed to depict the internal structure of the tailgate assembly, the supplemental tailgate apparatus being shown in phantom in a partially raised position;  
         [0027]      FIG. 3  is an elevational view of the tailgate assembly looking from the aspect of the inner panel with the inner panel removed to depict the internal structure of the tailgate assembly;  
         [0028]      FIG. 4  is a perspective view of the tailgate assembly with the inner panel removed, as depicted in  FIG. 3 ;  
         [0029]      FIG. 5  is an enlarged partial top perspective detail view, taken from the aspect of the inner panel, of a guide tube mounted on the C-channel and received through the strainers for mounting at the bottom of the tailgate assembly, the mounting bracket for the optional grab handle being shown mounted to the C-channel;  
         [0030]      FIG. 6  is an enlarged partial perspective detail view, taken from the aspect of the outer panel, of the C-channel and first strainer with the mounting bracket for the optional grab handle depicted, the mounting bracket for the guide tube being shown in phantom exploded away from the C-channel;  
         [0031]      FIG. 7  is an enlarged partial perspective detail view of the C-channel, guide tube and grab handle mounting bracket taken from the aspect of the inner panel;  
         [0032]      FIG. 8  is an enlarged partial perspective detail view of the guide tube with mounting bracket and the grab handle mounting bracket, with the C-channel being removed for purposes of clarity;  
         [0033]      FIG. 9  is a top plan view of the C-channel member;  
         [0034]      FIG. 10  is a upper perspective view of the central portion of the C-channel; and  
         [0035]      FIG. 11  is an enlarged elevational view of the guide tubes, mounting brackets and latch striker with the C-channel, strainers and outer shell of the tailgate being shown in phantom. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0036]     Referring to  FIGS. 1-4 , a tailgate assembly for pivotally mounting on a pick-up truck cargo bed incorporates the principles of the instant invention. Any left and right references are used as a matter of convenience and are determined by standing at the rear of the cargo bed where the tailgate is pivotally mounted and facing the cargo bed, the normal direction of travel of the pick-up truck. The tailgate assembly  10  is configured for the mounting of a supplemental tailgate apparatus  20  of the type disclosed in U.S. Pat. No. 6,918,624, granted on Jul. 19, 2005, to Scott Miller, et al, the contents of which are incorporated herein by reference in its entirety. Furthermore, the supplemental tailgate apparatus  20  can have associated therewith an optional grab handle device (not shown), which is disclosed in U.S. patent application Ser. No. 11/236,133, of Steve Bruford, et al, entitled “Grab Handle for Use with Supplemental Tailgate on Pick-Up Trucks”, now U.S. Pat. No. ______ , granted on ______, the contents of which are incorporated herein in its entirety by reference.  
         [0037]     The pick-up truck is conventionally manufactured with a cargo bed forming the rearward portion of the vehicle. The cargo bed generally includes generally vertical, upright side walls having a floor member extending generally horizontally therebetween. The tailgate assembly  10  extends transversely above the floor between the side walls at the rearwardmost portion of the cargo bed. The tailgate assembly  10  is pivotally mounted at the floor of the cargo bed and is movable between an upright closed position that is oriented perpendicularly to the floor and a lowered open position that forms an extension of the floor rearwardly of the side walls.  
         [0038]     A supplemental tailgate apparatus  20  of the type shown and described in U.S. Pat. No. 6,918,624 can be stored within the interior of the tailgate assembly  10  until deployed with the tailgate assembly  10  lowered into the open position and the supplemental tailgate apparatus  20  oriented generally vertically to serve as a substitute tailgate while the top surface of the lowered tailgate assembly  10  serves as an extension of the cargo bed. The supplemental tailgate apparatus  20  is also pivotally movable into a lowered position such that the cross member  22  is lower than the main tailgate structure. As is disclosed in the aforementioned U.S. Pat. No. 6,918,624, the cross member  22  can also incorporate a flip-out step member (not shown) that enhances the use of the cross member  22  as a step.  
         [0039]     With the supplemental tailgate  20  positioned below the main tailgate structure  10  to perform the step function of the supplemental tailgate  20 , a user of the apparatus  20  can step upon the cross member  22 , and any extended step member (not shown) if provided, and be assisted in making the next step on onto the inner panel (or top surface in the open position)  12  of the lowered tailgate assembly  10 , thereby providing physical access to the cargo bed and anything stored thereon. Ingress onto the cargo bed, may be facilitated by the use of a grab handle assembly (not shown) by which the person steps onto the cross member  22  of the lowered supplemental tailgate apparatus  20  can be stabilized while ascending the supplemental tailgate  12  onto the top surface  12  of the lowered tailgate assembly  10 . As disclosed in U.S. patent application Ser. No. 11/236,133, the grab handle assembly can be deployed to assist a person descending from the main tailgate assembly  10  to the surface of the ground through the use of the supplemental tailgate apparatus  20 .  
         [0040]     The supplemental tailgate apparatus  20  cannot be housed in a conventional tailgate as the enclosed structure of the tailgate will not allow the passage of the shaft or shafts connected to the cross member  22  or the guide tubes  25 , which preferably receive the shafts, through the interconnected inner and outer panels  12 ,  14  and internal strainers, or transverse support members,  15 ,  18 . Furthermore, the conventional assembled sheet metal tailgate assembly  10  would not have sufficient structural support for the mounting of a supplemental tailgate apparatus  20 , particularly if used as a step function.  
         [0041]     Referring to  FIGS. 1-11 , the structural configuration of the tailgate assembly  10  is modified to include an upper frame support, or reinforcement, member, preferably in the form of a C-channel  30 , that extends transversely at or near the top of the tailgate assembly  10 . The inner and outer panels  12 ,  14  can be connected to the reinforcement member, preferably in the form of the C-channel  30 , by welding or by a hemming process in which the edges of the panel  12 ,  14  are folded over a vertical edge of the structural frame member  30  and crimped thereto. Preferably, the inner panel  12  is welded to the inside upright leg  31  of the C-channel  30 , while the outer panel  14  is hemmed over top of the outside upright leg  33  of the C-channel  30 . The lowermost web  34  of the C-channel  30  extending between the upright legs  31 ,  33  is oriented substantially horizontal (when the tailgate assembly  10  is in the closed, upright position, and forms a U-shaped cross-sectional configuration. The C-channel  30  is also formed with a flanged opening  36  in the web  34  for each guide tube  25  utilized in the supplemental tailgate apparatus  20 .  
         [0042]     Preferably, the tailgate assembly  10  is formed with a pair of transversely extending reinforcement members  15 ,  18 , commonly referred to as “strainers”, although some conventional tailgates are formed with only one strainer in the interior of the tailgate assembly  10 . Preferably, the strainers  15 ,  18  are welded to the inner panel  12  and affixed to the outer panel  14  through adhesives. To accommodate the vertical passage of the guide tubes  25  through the strainers  15 ,  18 , the strainers are formed with a flanged depression notch  16  to establish a passageway for the reception of the guide tube  25  therethrough. The formation of flanges extending generally vertically (perpendicularly to the major axis of the strainers  15 ,  18 ) minimizes scratching of the exterior coating placed on the guide tubes  25  while the guide tubes  25  are being installed into the tailgate assembly  10 , providing a lead-in feature for the installation of the guide tubes  25 . The guide tubes  25  can then pass from the C-channel  30  through the strainers  15 ,  18  to the bottom of the tailgate assembly where they can be detachably affixed by a bolt inserted through the hole  29 . Alternatively, particularly if a reinforcement member (strainer) is placed at or near the bottom of the guide tube  25 , the guide tube  25  can be detachably connected to the strainer to positionally fix the guide tube  25  within the tailgate assembly  10 .  
         [0043]     The top of each guide tube  25  is preferably affixed by welding to a mounting bracket  26  that is oriented generally perpendicularly to the vertical axis of the guide tube  25 . The mounting bracket  26  has an opening  27  that is alignable with the interior of the guide tube  25  and alignable with the opening  36  in the C-channel. The mounting bracket  26  is also preferably formed with bolt holes  28  to permit the detachable connection of the mounting bracket  26  to the C-channel. Once the guide tube  25  and mounting bracket  26  are connected, the guide tube  25  can be inserted through the opening  36  in the C-channel and passed through the depression notches  16  in the strainers  15 ,  18  until the mounting bracket engages the web  34  of the C-channel. Connecting the mounting bracket  26  to the C-channel  25  with removable bolts enables the guide tubes to be removable for repair or replacement. The mounting bracket  26  includes support members  40  for the pivoting and deployment of the telescopic support shafts  21  of the supplemental tailgate apparatus  20 .  
         [0044]     The C-channel  30  can also support a mounting bracket  38  that is bolted to the underside of the web  34  using the fasteners connecting the corresponding mounting bracket  26  for the guide tube  25  to the top surface of the C-channel web  34 . The grab handle mounting bracket  38  can also be bolted or welded to the top strainer  15 . The grab handle mounting bracket  38  is formed in a manner to wrap around the corresponding guide tube  25  so as to avoid interference therewith and supports a mounting flange  39  for use in attaching and deploying the grab handle, as is described in the aforementioned U.S. patent application Ser. No. 11/236,133.  
         [0045]     The upper reinforcement member  30 , as is best seen in  FIGS. 9-11 , also serves to mount a striker  44  for a latch mechanism (not shown) that is formed as part of the supplemental tailgate apparatus  20 , which retains the supplemental tailgate apparatus  20  in the stored position within the tailgate assembly  10  until extension thereof is desired. The C-channel  30  is also provided with locator holes  46 ,  48  adjacent to the flanged openings  36  for the passage of the guide tubes  25  to be cooperable with NAB (no-adjust build) pins  49  that are detachably mounted on the mounting bracket  26  and insertable within the locator holes  46 ,  48  to facilitate the proper positioning of the supplemental tailgate apparatus  20  for a flush fit with the exterior sheet metal of the tailgate assembly  10 . Preferably, the NAB pins  49  are detachably fastened to the mounting bracket  26  within an oversize hole to permit positional adjustment thereof for proper seating and positioning of the NAB pin  49 .  
         [0046]     The modified tailgate assembly  10  is preferably formed by welding the inner panel  12  to the C-channel  30  and the strainers  15 ,  18 . The assembled guide tubes  25  with mounting brackets  26  can be inserted through the flanged openings  36  in the C-channel  30  and through the flanged notches  16  of the strainers  15 ,  18 . Fasteners (not shown) connect the mounting bracket  26  to the web  34  of the C-channel  30 . These same fasteners (not shown) can also be used to mount the grab handle mounting bracket  38  to the underside of the web  34 . An additional fastener (not shown) can be utilized to secure the bottom end of the guide tubes to the inner panel  12 , or via a bracket (not shown) that can mount on the lower strainer  18 . After the guide tubes  25  are secured, the outer panel  14  can be mounted on the assembly  10 , preferably by hemming the edges around the corresponding edges of the inner panel  12 , the outside upright leg  33  of the C-channel  30 , and other appropriate conventional mounting structure (not shown). Once the supplemental tailgate apparatus  20  is installed, the tailgate assembly  10  is available for mounting on the pick-up truck.  
         [0047]     One skilled in the art will recognize that changes in the details, materials, steps and arrangements of parts which have been described and illustrated to explain the nature of the invention will occur to and may be made by those skilled in the art upon a reading of this disclosure within the principles and scope of the invention. The foregoing description illustrates the preferred embodiment of the invention; however, concepts, as based upon the description, may be employed in other embodiments without departing from the scope of the invention.  
         [0048]     For example, some pick-up truck tailgates are manufactured in a manner that a single piece of sheet metal is bent and folded to form both the inner and outer panels which can be joined at the top to establish the shell of the tailgate assembly defining the interior cavity thereof. Such tailgate configurations are intended to be encompassed within the modifications described herein. Furthermore, the upper frame support is preferably a C-channel oriented into a U-shaped position; however, one skilled in the art will understand that other formed frame support members can be utilized to provide similar features. Similarly, the tailgate assembly can utilize one, two or more reinforcement members, or strainers, within the interior of the tailgate shell.