Abstract:
A module in the form of an applique is mountable on an exterior surface of a vehicle liftgate and provides a mounting platform for a plurality of components mountable on the liftgate in a single assembly operation. The components include at least two of light sources in the form of LEDs or incandescent bulbs, an actuatable switch, a camera and a wash fluid dispensing nozzle. The components are mounted on a substrate in the form of a printed circuit board or a lead frame attached to a substrate for mounting in a carrier. The carrier is affixed to the module and is alignable with apertures in the applique for transmission of light from the light sources exteriorly of the applique as well as to enable the camera to view a field of view through the lens. The electric switch is actuatable by a resilient membrane mounted on the carrier and actuatable exteriorly of the applique.

Description:
BACKGROUND  
         [0001]    The present invention relates, in general, to motor vehicle liftgates or rear batches and, more specifically, to accessory components mounted on such vehicle liftgate or rear hatches.  
           [0002]    In modern vehicles, larger vehicles such as SUVs, vans and station wagons have a liftgate or rear hatch which closes a rear opening in the vehicle body. The liftgate is pivotally attached, usually by hinges, to the vehicle body structure surrounding the rear opening. The liftgate is releasably latchable to the vehicle structure by a latch mechanism so as to be movable between a closed position latched to the vehicle body structure and a pivoted, open position allowing access to the interior of the vehicle through the rear opening.  
           [0003]    The liftgate itself is formed of a panel structure, which is stamped or otherwise formed into a panel having an upper opening for receiving a glass window. An interior trim panel is attachable to the liftgate panel to cover components mounted on the gate.  
           [0004]    The liftgate forms a platform for a number of different accessories or components, such as a flipglass latch, a wiper motor and associated wiper arm, license plate lights, and a wash pump and/or wash nozzle. Various lights as well as the center high mounted stop light may also be mounted on the liftgate along with the liftgate latch mechanism. Other components which are usually mounted on the liftgate can include electrical contact connections to the defrost grid mounted on the liftgate glass or fiberglass.  
           [0005]    All of these accessories or components are manufactured separately from the liftgate panel structure and are mounted, usually one at a time, on the liftgate while the vehicle is being assembled. The mounting of each component on the liftgate panel either directly or through brackets typically requires mechanical fasteners and, usually, an electrical connection via a plug-in connector, screw terminal, etc. All of the mounting procedures, and the mechanical and electrical connections require time, multiple workers and an increased length on the vehicle assembly line. In addition, although each component can be tested at its manufacturing site, the numerous multiple mechanical and electrical connections all create additional sources of defects which may require additional checking after assembly on the liftgate.  
           [0006]    As can be seen, all of these factors lead to a substantial assembly time for the liftgate thereby resulting in a higher than desirable cost. To address these problems, a modular approach has been proposed in which several components are separably manufactured, pretested, and assembled into a single module, with only the module having to be mounted in a single operation on a liftgate. The number of separate mechanical fasteners and electrical connections can also be reduced by this modular approach. However, the modular approach has been proposed only for a limited number of components. This has resulted in less than anticipated savings in assembly time and labor.  
           [0007]    Thus, it would be desirable to provide an improved modular component apparatus for vehicle liftgates in which multiple components are mounted in a single module for a single installation on the liftgate thereby improving reliability and reducing assembly costs. It would also be desirable to provide a modular component apparatus for a vehicle liftgate which has pre-aligned connection points, combined mounting points, and reduced weight which provides an increased glass viewing area.  
         SUMMARY  
         [0008]    The present invention is an accessory component module for a vehicle liftgate which unitarily carries a plurality of components which can be mounted on a vehicle liftgate in a single assembly operation when the module itself is mounted on the liftgate.  
           [0009]    In one aspect, the present module is in the form of a body having a plurality of individual components mounted thereon prior to mounting of the body of the module on a vehicle liftgate. The components include at least two of light sources, a camera and an actuator or switch.  
           [0010]    When a camera is one of the components mounted on the body of the module, a camera lens is exposable through the body of the module, preferably through an aperture. A transparent cover may be mounted over the lens. A coating or a film may be disposed over the lens. An optional fluid dispensing nozzle may be mounted on the body for connection to a fluid conduit to enable cleaning fluid to be dispensed over the lens.  
           [0011]    In one aspect of the invention, a printed circuit board carrying conductive traces or a lead frame having formed conductive leads mounted on a substrate are mounted in a carrier which is separately mountable to the body of the module. A sealing or potting component may be disposed over the printed circuit board and the lead frame. The light sources and switch or actuator may be mounted on the printed circuit board or the lead frame prior to insertion in the carrier.  
           [0012]    In another aspect, the carrier is formed of a transparent material to enable light emitted by the light sources to be transmitted through the carrier and externally of the body of the module through apertures in the module. Alternately, removable lenses or covers may be attached to the carrier over apertures in the carrier to enable replacement of the light sources without removing the module from the liftgate.  
           [0013]    In another aspect, an electrical harness is directly mounted on the printed circuit board or on the lead frame to provide connections to external vehicle conductors or harnesses.  
           [0014]    The component module of the present invention provides significant advantages over previous liftgate accessory or component mounting methods by incorporating a plurality of liftgate components into a unitary module which can be attached to the liftgate in a single assembly operation. This improves the reliability of the components since the components can be preassembled, pretested and even pre-wired either before or after mounting on the module. The number of workers required to mount all of the components on the liftgate in the vehicle assembly line is reduced along with line length and assembly time. This reduces the overall costs of the liftgate components for more economical and efficient manufacturing operation. In addition, the number of electrical connectors and mechanical connection points are reduced for the liftgate to again reduce assembly time, cost and to improve reliability.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWING  
       [0015]    The various features, advantages and other uses of the present invention will become more apparent by referring to the following detailed description and drawing in which:  
         [0016]    [0016]FIG. 1 is a perspective view of an exemplary vehicle liftgate utilizing the applique module according to the present invention;  
         [0017]    [0017]FIG. 2 is a bottom perspective view of the applique shown in FIG. 1;  
         [0018]    [0018]FIG. 3 is rear perspective view of the applique shown in FIGS. 1 and 2;  
         [0019]    [0019]FIG. 4 is an enlarged perspective view generally similar to FIG. 3;  
         [0020]    [0020]FIG. 5 is a perspective view of the component carrier;  
         [0021]    [0021]FIG. 6 is a perspective view of the printed circuit board mounted in the carrier of FIG. 5 for one aspect of the present applique module;  
         [0022]    [0022]FIG. 7 is a cross-sectional view, generally taken along line  7 - 7  in FIG. 5;  
         [0023]    [0023]FIG. 8 is a bottom perspective view of another aspect of an applique module according to the present invention;  
         [0024]    [0024]FIG. 9 is a perspective view of the component carrier used in the applique module shown in FIG. 8;  
         [0025]    [0025]FIG. 10 is a bottom perspective view of the carrier shown in FIG. 9;  
         [0026]    [0026]FIG. 11 is a perspective view of the lead frame and component assembly used in the carrier of FIGS. 9 and 10;  
         [0027]    [0027]FIG. 12 is a bottom perspective view of the lead frame and component assembly shown in FIG. 11; and  
         [0028]    [0028]FIG. 13 is a partial, enlarged perspective view of the electronic actuator handle used in the carrier shown in FIGS.  9 - 11 . 
     
    
     DETAILED DESCRIPTION  
       [0029]    Referring now to the drawing, and to FIG. 1 in general, there is depicted a pictorial representation of a motor vehicle liftgate or rear hatch  20 . The shape of the liftgate  20  will vary from vehicle to vehicle.  
         [0030]    The liftgate  20  is intended, by example only, to be articulated or pivoted about an upper generally horizontally extending edge  22  by means of hinges attached to the surrounding vehicle body structure, not shown. When the liftgate  20  is pivotally mounted about the upper edge  22 , the latch means will normally be associated with an opposed bottom edge  24 . The liftgate  20  may also be articulated to the vehicle body about a vertical axis on one of the lateral side edges, with the opposite lateral edge carrying a locking means for securing the liftgate  20  in a fixed position closing the rear opening in the vehicle.  
         [0031]    The liftgate  20  may be formed using any conventional manufacturing process, such as an outer panel  26  which is joined to an inner panel, not shown.  
         [0032]    An aperture or opening  30  is formed in the liftgate  20 . The aperture  30  is closed by a transparent panel  32 , such as a glass window. The window  32  may be fixedly attached to the rear liftgate panel  26  or, articulated itself about an upper generally horizontally extending edge  34  to the upper edge portion of the liftgate  20  by means of one or more hinges  36  for pivotal movement of the opposed bottom end  40  between a closed position, sealed to the liftgate  20  and an open, pivotal position spaced from the adjacent portions of the outer liftgate panel  26 . Such an articulated glass or window is commonly referred to as a flipglass.  
         [0033]    As shown in FIG. 1, a recess  42  can be formed in the liftgate outer panel  26  to provide a convenient mounting location for a vehicle license plate, not shown. According to the present invention, an applique  50  is mounted on the exterior surface of the liftgate outer panel  26  immediately above the recess  42  and below the bottom horizontally extending edge  40  of the liftgate window  32 . The applique  50  serves has a decorative outer surface consistent with the vehicle on which the liftgate  20  is mounted. The applique  50 , which is typically formed of a plastic material, can be color molded or painted to match the body and liftgate color of the vehicle. The applique or module  50  is formed of suitable plastic material, such as PC, ABS, PBT or compounds thereof.  
         [0034]    According to the present invention, the applique  50  serves as a component mount for various liftgate mounted accessories or components which enables such components to be pre-mounted, pre-wired and, if necessary, pre-tested before the applique  50  is mounted on the liftgate  20  in a single assembly operation.  
         [0035]    The applique  50  is shown more clearly in FIGS.  2 - 4 , will have a shape consistent with the mounting location of the applique  50  on the liftgate  20 . The applique  50  is typically in the form of a one piece body formed of molded plastic.  
         [0036]    By example only, the applique  50  has a smoothly curved center portion  52  which transitions, at one edge  54  into an angularly disposed flange  56 . The opposite edge of the center portion  52  likewise transitions into an arcuate flange  58  which extends substantially over the entire length of the applique  50  between opposed first and second ends  60  and  62 .  
         [0037]    An aperture  64  is formed intermediately between the first and second ends  60  and  62  in the center portion  52  for receiving the wiper motor drive shaft therethrough. The exterior end of the wiper motor drive shaft will be used for attachment of a wiper arm head.  
         [0038]    As shown in FIGS. 2 and 4, a centrally located boss  66  is formed in the flange  56  and extends outward from an exterior surface  68  of the flange  56 . The boss  66  is configured for serving as a mount for a camera or vision unit  70 , as described hereafter.  
         [0039]    Strengthening ribs  59  are formed laterally between the first and seconds ends  60  and  62  of the applique  50  and extend between the center portion  52  and the flange  58  for providing rigidity to the angularly disposed flange  58 .  
         [0040]    As seen in FIGS. 3 and 4, a plurality of spaced bosses  70  are integrally formed on the flange  58  and extend away from the flange  58  toward the liftgate  20  when the applique  50  is mounted on the liftgate  20 . The bosses  70  are threaded and receive one end of a threaded nut having a threaded shank portion and an enlarged, generally centrally located washer  74  which seats against the outer edge of the boss  70  when the stud  72  is threaded into the boss  70 . The exposed end of the stud  72  is insertable through an aperture, not shown, formed in the liftgate  20  and receives a tightenable nut to assist in fixedly mounting the applique  50  to the liftgate  20 .  
         [0041]    Additional mounts  76  are also provided on the applique  50  generally adjacent the edge  54  of the center portion  52 . The mounts  76  are laterally spaced between the first and second ends  60  and  62  and fit within raised, open-ended generally inverted U-shaped bosses  78  which can be integrally molded with or otherwise fixed by welding or adhesive, to the center portion  52  of the module  50 . A J-clip  80  is snap mountable over an edge of each boss  78  and traps the head of a threaded fastener  82  to the boss  78 . The exposed ends of the fastener  82  will likewise extend through apertures in the liftgate for receiving a tightenable nut to assist in fixedly mounting the module  50  against the liftgate  20 .  
         [0042]    The applique module  50  is designed for receiving a plurality of different components to enable such components to be mounted on the liftgate  20  in a single assembly operation, rather than individually as has been the case in prior liftgate constructions.  
         [0043]    One component mountable on the applique  50  is the camera or vision unit  70  which may be any suitable camera, such as a CCD camera or CMOS, which is capable of taking pictures in black and white or color of a field of vision provided by a camera lens  84 . An aperture  86  is formed on a bottom surface  88  of the boss  66  on the applique  50  for providing an opening through which the lens  84  is visible. Alternately, a transparent lens cover may be mounted in the aperture  86 , either permanently or by removable fasteners.  
         [0044]    As shown in FIG. 2, a nozzle  92  is mounted on the boss  66  in close proximity to the lens  84 . The nozzle  92  receives fluid via a conduit  94  shown in FIG. 4 from a suitable fluid supply. This enables the lens  84  to be cleared of frost, ice, snow, dirt or other debris when necessary.  
         [0045]    The camera or vision unit  70  is fixedly securable to the inner surface of the boss  66  by means of threaded fasteners  96  which are mountable in threaded stand-offs  98  integrally formed with the boss  66  or secured as separate members to the boss  66 .  
         [0046]    In place of or in addition to the nozzle  92 , cleaning of the lens  84  may be implemented in other ways. For example, a hydrophobic or hydrophilic coating can be applied to the exterior surface of the lens  84  to repel debris. A thin defrost grid could also be mounted in or over the lens  84  to provide heating to remove frost, ice or snow from the lens  84  without interfering with operation of the camera  70 .  
         [0047]    Camera power and video output cables  100  extend from the camera  70 , as shown in FIG. 4, for routing to a suitable camera output display device which is typically mounted in the interior in the passenger compartment of the vehicle.  
         [0048]    Another threaded boss  70  is formed on a lower edge of the boss  66  and receives a threaded stud  72  to assist in securing the lower edge  54  of the applique  50  to the liftgate  20 .  
         [0049]    In the aspect of the applique  50  shown in FIGS.  1 - 7 , the flange  56  on the applique  50  is formed with a plurality of spaced apertures  110 ,  112 ,  114 ,  116  and  118 . The apertures  110  and  116  cooperate with light sources, described hereafter, to provide illumination for a vehicle license plate mounted in the recess  42  on the liftgate  20 . The apertures  112  and  114  cooperate with light sources used to provide additional illumination for the camera  70 .  
         [0050]    The aperture  118  cooperates with an electronic actuator or switch mountable within the applique  50 , as described hereafter, to provide an electrical actuation signal for use in operating a component mounted on the liftgate, such as a flip glass latch used to releasably latch the window  32  in a closed, sealed position on the liftgate  20 , but allowing the bottom edge  40  of the glass  32  to be released from the latch and pivoted away from the liftgate  20  to an open position about the top mounted hinges  36 .  
         [0051]    It will be understood that although the apertures  110 ,  112 ,  114  and  116  are shown as being completely open, transparent covers, such as lens covers, may be mounted in the apertures  110 ,  112 ,  114  and  116  to seal the interior of the applique  50  while still allowing light from the associated light sources to pass therethrough.  
         [0052]    According to a unique feature of the present invention, individual light sources and the switch actuated by the electronic handle are mounted on a support, such as a printed circuit board  130  in the aspect of the applique  50  shown in FIGS.  1 - 7 , the printed circuit board  130  is formed with an elongated, strip-like shape according to conventional circuit board techniques. Individual electrical conductive traces are formed in the circuit board  130  to provide connection between light sources  132 ,  134 ,  136  and  138  as well as a switch means, such as a microswitch  140 . Although the light sources  132 ,  134 ,  136  and  138  may comprise any suitable light source, such as an incandescent bulb, one or a cluster of LEDs are employed as the light sources  132 ,  134 ,  136  and  138 , with one LED being shown as a pictorial example of each light source. Each LED  132 ,  134 ,  136  and  138  is secured to the printed circuit board  130  by solder or a press-in, snap connection to suitable leads to provide the desired current when the light sources are to be activated. Similarly, the switch  140  is mounted to suitable traces in the printed circuit board  130  to provide an output signal when the associated spring biased cover member  142  described hereafter, is depressed or touched.  
         [0053]    Output signals from an electrical power to the traces in the printed circuit board  130  is provided by one or more conductors shown pictorially by reference number  144 .  
         [0054]    According to a unique of the applique  50 , the printed circuit board  130  is sealingly mounted in a carrier denoted by reference number  150 . The carrier  150  is formed with an upper trough section defined by an intermediate shoulder  152  which acts as a mounting seat for the printed circuit board  130 . The upper portion of the trough-like section above the printed circuit board  130  can be filled with a suitable sealing or potting material  154  to seal the interior of the carrier  150  and the electrical components mounted on the printed circuit board  130 .  
         [0055]    Mounting flanges  165  project outwardly from opposite ends of the carrier  150  and have apertures formed therein for receiving a fastener  82  therethrough to enable the carrier  150  to be fixedly secured to the applique  50 .  
         [0056]    Individual pockets or receptacles  156 ,  158 ,  160 ,  162  and  164  are formed below the shoulder  150  along the length of the carrier  150 . The chambers are laterally spaced and provide a chamber for one of the light sources  132 ,  134 ,  136  and  138  or the microswitch  140  associated with the electronic handle actuator  142 .  
         [0057]    The carrier is preferably formed of a suitable lightweight, plastic material. At least the lower portion of each chamber  156 ,  158 ,  160 ,  162  and  164  is transparent to allow light from the light sources  132 ,  134 ,  136  and  138  to pass through the carrier and the associated aperture in the flange  56  externally of the applique  50 . The lower portion of each chamber  156 ,  158 ,  160  and  162  can be integral with the carrier  150 , or can be mounted on the carrier  150  as a separate element as shown in FIG. 8.  
         [0058]    In the case of the electronic actuator  142 , the actuator  142  is typically in the form of a resilient membrane mounted internally to the bottom edge of the chamber  164  in a sealed manner. The center portion of the actuator membrane is movable against a plunger  141  of the switch  140  through an actuator spring  234  shown in FIG. 13 to provide an output signal from the switch  140  via switchable contacts in the switch housing.  
         [0059]    In using the applique  50 , the individual light sources  132 ,  134 ,  136  and  138  are pre-mounted on the printed circuit board  130  along with the switch  140 , the actuating spring  234  and the member  142  are then mounted in the carrier  150  of the applique  50 . The entire carrier  150  is then secured to the flange  56  of the applique  50  using the same inverted U-shaped bosses  78 , J-clips and fasteners  82  described above. The camera  70  can also be mounted to the boss  66  by the fasteners  96 .  
         [0060]    The applique  50  is then mountable to the liftgate  20  in a single assembly operation, possibly by a single worker. The threaded studs  72  and the fasteners  80  are inserted through the appropriate apertures in the liftgate outer panel  26  and receive a tightenable nut which is rotated to a tightened state to fixedly, yet releasably secure the applique  50  to the liftgate  20 . The individual electrical connections to the conductors  144  from the printed circuit board  130  can then be attached by screw terminals, soldering, etc., plug together connectors, etc. Likewise, the output signal from the camera  70  as well as the power supply to the camera  70  can also be provided by screw connections, snap together connectors, soldering, etc.  
         [0061]    Referring now to FIGS.  8 - 13 , there is depicted another aspect of an applique module  200  according to the present invention. The applique module  200  is constructed similar to the applique  50  in terms of shape, as well as the components mounted thereon. Thus, the applique  200  includes a boss  66  for receiving a camera.  
         [0062]    In this aspect, the printed circuit board  130  is replaced with a lead frame assembly  210  in the carrier  150 . In the lead frame assembly, stamped or otherwise formed electrically conductive leads are all denoted by reference number  212  are mounted on a substrate  214  in a configuration to provide power to an output signals from various components electrically connected to the individual leads  212 . Thus, incandescent bulbs  216  and  218 , or LEDs, are secured, such as by solder, to selected leads  212 . Individual LEDs  220  and  222  are likewise soldered to the leads  212 . Mirrored reflectors  224  are optionally mountable about each LED to enhance the illumination provided by each LED  220  and  222 . The reflectors can be fixedly mounted to the substrate  214 . A switch  230 , similar to the microswitch  140  is also mounted by soldered, welded, or plugs to output terminals to the leads  212  to provide an actuation signal upon movement or depression of the electronic handle or membrane denoted by reference number  232  in FIGS. 8 and 9.  
         [0063]    As more clearly shown in FIG. 13, a somewhat rigid actuator spring  234  is disposed between the membrane  232  and the substrate  214 . Biasing arms  236  extend between a base portion of the spring  234  and the substrate  214  to bias the plate  234  normally away from the substrate  214 . However, depression of the membrane  232  will cause the plate  234  to overcome the biasing force provided by the spring arms  232  and enable the plate  234  to depress the plunger on the switch  230  to generate an output signal from the switchable contact carried in the switch  230 .  
         [0064]    This aspect of suitable electrical connections via individual conductors  240  or a cable or harness may be employed to connect the individual leads  212  to an outside source of power, as well as to direct actuating signals from the switch  232  to the receiving unit.  
         [0065]    As shown in FIGS.  8 - 13 , the substrate  214  is formed with a plurality of hangers, each denoted by reference number  244  which can be integrally formed with the substrate  214  or attached thereto by suitable adhesive, sonic welding, heat welding, etc. Each hanger  244  has inverted U-shaped hanger elements  246  extending from at least one side edge of the substrate  214  at spaced locations along the length of the substrate  214 .  
         [0066]    The hangers  244  are designed and positioned for snap engagement with opposed side edges of a carrier  250 . In this manner, the substrate  214  which may be formed of one or more individual substrate members, is fixedly held in position within the carrier  250 . Although not shown, a suitable sealing or potting material may be placed within the upper portion of the carrier  250  to seal off the substrate  214  and the electrical connections and components mounted on the opposite side within the interior of the carrier  250 .  
         [0067]    As shown in FIGS. 9 and 10, the carrier  250  forms an elongated receptacle having a plurality of sections for receiving any number, type and combination of components, such as the membrane  232 , to allow light to escape through an opening or lens cover from the LEDs  220  and  222 , or to allow light to be transmitted from the incandescent bulbs  216  or  218 .  
         [0068]    The carrier  250  is provided with at least three-sided walls  260  and  262  which extend from an outer surface of the carrier so as to engage the sidewalls of apertures  264  and  266  in the flange  56  of the applique  200 . Light or lens covers  268  and  270  are removably attached to the carrier  250  by means of threaded fasteners or screws  272 . The interface between the lens covers  268  and  270  and the carrier  250  is sealed by a gasket or other sealing mechanism, not shown. This enables the lens cover  268  and  270  to be removed from the carrier  250  externally of the applique  200  for replacement of the bulbs  216  or  218 . An aperture  274  is also formed in the flange  250  for exposing the end of a receptacle  276  in the carrier  250  which carries the actuator membrane  232 .  
         [0069]    The carrier  250  and the lens covers  268  and  270  are also usable with the LEDs  132 ,  134 ,  136  and  138 .  
         [0070]    The applique  200  provides the same one assembly operation mounting of a plurality of individual components to the liftgate  20  as does the applique  50 . Both appliques reduce overall weight, simplify the assembly process by significantly reducing the assembly time, the number of workers required to mount the components on the liftgate, as well as increasing reliability of the applique and the components mounted thereon since such components have been mounted separately from the vehicle assembly operation and pretested if necessary thereby increasing the reliability of such components. The applique  200  can be equipped with many different components in addition to those described herein, such as a vehicle sealing gaskets, sealing foam, wiper arm park ramp, sensors, emitters, etc.