Patent Publication Number: US-2003221305-A1

Title: Tailgate accessory attachment system

Description:
BACKGROUND OF THE INVENTION  
       [0001] The instant invention describes means of attaching accessories to the tailgates of pickup trucks. Pickup truck tailgate accessories that can be mounted using the herein described attachment system include, among others, the tailgate mounted drag reducing aerostabilizers described in applicant&#39;s U.S. Pat. Nos. 5,688,020; 5,871,254; and 6,012,762.  
       SUMMARY OF THE INVENTION  
       [0002] A primary purpose of the instant invention is to provide a method for securely attaching an accessory item to an upper portion of a tailgate of a pickup truck.  
       [0003] A related object of the invention is that it include a positioning device for locating the attachment means for the accessory item.  
       [0004] A further related object of the invention is that the positioning device be formed such that it references a forward surface of the tailgate to establish location of the accessory item attachment means.  
       [0005] Yet another related object of the invention is that positioning device is, at least in part, formed in an L-shape.  
       [0006] Another object of the invention is that the accessory item attachment means be affixed to the tailgate at a location established by the positioning device.  
       [0007] A related object of the invention is that a fastener portion of the accessory item attachment means be positioned, as seen with the tailgate vertical, at least three-forth of an inch aft of and no more than one and one-half inches aft of a forward surface of the tailgate proximal to and forward of the fastener portion of the accessory item attachment means.  
       [0008] A further related object of the invention is that a fastener portion of the accessory item attachment means be positioned, as seen with the tailgate vertical, at least one inch aft of and no more than one and one-fourth inches aft of a forward surface of the tailgate proximal to and forward of the fastener portion of the accessory item attachment means.  
       [0009] Yet another object of the invention is that it further includes a fastener portion of the accessory item attachment means.  
       [0010] A directly related object of the invention is that said fastener portion that fastens the accessory item attachment means to the tailgate be a screw-like device.  
       [0011] Still another object of the invention is that the accessory item attachment means fit into an opening in the accessory item.  
       [0012] A related object of the invention is that a receptacle member be disposed in the opening in the accessory item.  
       [0013] A further object of the invention is that there be a locating opening in said positioning device with said locating opening used to position a tool used to make a hole in an upper portion of the tailgate.  
       [0014] Yet another object of the invention is that the accessory item attachment means be, at least in part, curvilinear in shape.  
       [0015] Still another object of the invention is that there be more than one accessory item attachment means.  
       [0016] Another object of the invention is that there be a forward fastener that fastens the accessory item to a forward portion of the tailgate.  
       [0017] It is a related object of the invention that the forward fastener be in mechanical communication with the accessory item and a forward portion of the tailgate proximal said accessory item attachment means.  
       [0018] A further object of the invention is that the forward fastener that fastens the accessory item to the forward portion of the tailgate be a screw-like device.  
       [0019] A further object of the invention is that the forward fastener that fastens the accessory item to a forward portion of the tailgate, as seen with the tailgate vertical, is at least one inch below an upper surface of the tailgate proximal the accessory item attachment means.  
       [0020] Yet another related object of the invention is that the forward fastener that fastens the accessory item to a forward portion of the tailgate, as seen with the tailgate vertical, is at least one and one-fourth inch below an upper surface of the tailgate proximal the accessory item attachment means.  
       [0021] Another object of the invention is that there be multiple forward fasteners that fasten the accessory item to a forward portion of the tailgate.  
       [0022] Still another object of the invention is that the accessory item attachment means includes a seal member.  
       [0023] A directly related object of the invention is that said seal member be at least in part an O-ring.  
       [0024] Yet another object of the invention is that the accessory item attachment means be blind.  
       [0025] A further object of the invention, in one of its optional embodiments, is that the positioning device be discarded after use for positioning the attachment means.  
       [0026] Another optional object of the invention is that the positioning device remains on the tailgate after installation of the accessory item to the tailgate.  
       [0027] A related object of the invention is that at least a portion of the accessory item attachment means be affixed to the positioning device.  
       [0028] An optional object of the invention is that a positioning device for locating and attaching an accessory item on an upper portion of the tailgate further include an accessory item attachment means.  
       [0029] A directly related object of the invention is that, if the positioning device includes the accessory item attachment means, that the accessory item attachment means can be disposed differently than the location requirements given previously in this section.  
       [0030] Still another object of the invention is that the accessory item be an aerostabilizer.  
       [0031] Yet another object of the invention is that said accessory item be an aerostabilizer that includes stanchions that are in communication with the tailgate.  
       [0032] Another object of the invention is that an accessory item attachment means be in mechanical communication with an upper surface of the tailgate and insertable into an opening in the accessory item.  
       [0033] A related object of the invention is that there be a receptacle disposed between the opening in the accessory item and the accessory item attachment means such that the receptacle serves as the opening that the accessory item attachment means inserts into. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0034]FIG. 1 shows a portion of a pickup truck with its tailgate closed in the vertical position. Also shown is a positioning device in the form of an angle member here that is used to locate holes used for fasteners in an upper surface of the tailgate. The fasteners are part of an accessory item attachment means that are subsequently used to aid in fastening an accessory item to the tailgate. An electric drill with a drill bit for making the holes is also illustrated. Examination of virtually all makes of pickup trucks has established that the front surfaces and the upper surfaces of their tailgates are perpendicular to each other over at least a portion of their surfaces. This is an important characteristic that has been utilized in developing the instant invention.  
     [0035]FIG. 2 illustrates how the accessory item fastener means, in their preferred embodiment, are attached to the tailgate by sheet metal screws. The electric drill here has a screwdriver bit installed. Note that it is also possible to use self tapping screws in which case there would be no need to drill the holes that was done in FIG. 1.  
     [0036]FIG. 3 shows how the accessory item is then positioned on the tailgate by forcing it down onto the accessory item fastener means. Note that the accessory item shown here is an aerostabilizer that is the subject of earlier patents discussed in an earlier section of this application titled “BACKGROUND OF THE INVENTION”.  
     [0037]FIG. 4 depicts how forward fasteners, here shown as sheet metal screws, are then installed to add strength in the attachment of the accessory item to the tailgate.  
     [0038]FIG. 5 is a similar situation as that presented in FIG. 1; however, in this instance the positioning device will remain on the tailgate after installation of the accessory item. Note the holes for forward fasteners in the positioning device.  
     [0039]FIG. 6 presents a similar operation as FIG. 2 except that the positioning device remains on the tailgate.  
     [0040]FIG. 7 is the same view and operation as that presented in FIG. 3 with the exception that the positioning device remains in place.  
     [0041]FIG. 8 illustrates the completion of the installation of the accessory item as does FIG. 4 except the positioning device remains in place on the tailgate in this FIG. 8.  
     [0042]FIG. 9 is a partial cross sectional view, as taken through the attachment fasteners of FIG. 4, that shows the upper attachment means and its preferred fastener, a sheet metal screw in this instance, and how they insert into the accessory item. Note that a receptacle member, in this case a bushing-like device, is disposed between the opening in the accessory item and the upper attachment means to add structural integrity. Note that the dimensions A and B shown here are used to define the best location of the fasteners on most all pickup truck tailgates.  
     [0043]FIG. 10 shows a similar cross section to that presented in FIG. 9 except a cargo bedliner has been installed that extends up onto the forward surface of the tailgate. The installation of the cargo bedliner does not change dimensions A and B. The A and B dimensions have been established based on a critical review of all pickup truck tailgates both with and without bedliners. Further, an alternative design of the upper attachment means is presented here. This upper attachment means includes an integral fastener and, as a further option, an O-ring that makes for a more secure fit and also acts as a moisture barrier.  
     [0044]FIG. 11 is a partial cross sectional view through a typical fastener system as presented in FIG. 8. In this case the positioning device remains in place as an integral part of the installation of the accessory item.  
     [0045]FIG. 12 presents one more option in the form of a cross sectional view similar to FIG. 11. Note that in this option the accessory item upper fastener means is attached directly to the positioning device. Installation of this configuration would be slightly different that the procedure outlined in FIGS  5  and  6  in that the accessory item upper fastener means are attached to the positioning device before it is installed on the tailgate. 
    
    
     DETAILED DESCRIPTION  
     [0046]FIG. 1 shows a portion of a pickup truck  39  with its tailgate  38  closed in the vertical position. A positioning device  36  for positioning an accessory on the tailgate  38  is used to locate holes drilled into the top of the tailgate by means of the positioning device&#39;s openings  37 . This positioning device  36  is normally made in an L-shape so that it can reference either the top and/or the front of the tailgate  38 . An electric drill  33  and a drill bit  34  are used for making holes in the tailgate  38  here although any other method for making a hole in the tailgate  38  is acceptable.  
     [0047]FIG. 2 is a similar view to that presented in FIG. 1 except the positioning device has been removed and attachment means  42  for attaching an accessory item to the tailgate are being installed. The preferred embodiment of the attachment means  42  and its fastener  43  are shown in an enlarged view for illustrative purposes. An electric drill  33  and screwdriver bit  35  are shown to illustrate how the attachment means  42  is installed.  
     [0048]FIG. 3 illustrates how a tailgate mounted accessory  31 , in this case an aerostabilizer, is installed by applying a force that is illustrated by force arrow  40 . Shown here also are the preferred stanchions  32  that are used as part of Applicant&#39;s tailgate mounted aerostabilizers.  
     [0049]FIG. 4 illustrates the preferred method of installing forward fasteners  44 , in this case sheet metal screws, to attach the front of the tailgate mounted accessory  31 . While the tailgate  38  is shown down or horizontal here, the forward fasteners  44  can be installed with the tailgate  38  in any orientation. Note that the forward fasteners  44  are being installed into stanchions  32  that are part of the tailgate mounted aerostabilizer here. Other tailgate accessories, including other variations of aerostabilizers, may not have the stanchions but would still be considered to be within the spirit and scope of the instant invention.  
     [0050]FIG. 5 is essentially the same drawing as presented in FIG. 1 except there are front openings  47  in the positioning device  36 . The reason for these openings  47  is that the positioning device  36  stays in place on the tailgate  38  in this concept. As such, the openings  47  are there to allow the forward fasteners to pass through the positioning device  36 .  
     [0051]FIG. 6 is the same as the drawing presented in FIG. 2 except the positioning device  36  remains in place on the tailgate  38 .  
     [0052]FIG. 7 presents the same drawing as that shown in FIG. 3 but with the positioning device  36  still disposed on the tailgate  38 .  
     [0053]FIG. 8 shows the positioning device  36  remaining on the tailgate  38  as the installation of the forward fasteners  44  completes the installation of the accessory item on the tailgate  36 .  
     [0054]FIG. 9 is a partial cross-sectional view, as taken through a section that includes both the accessory item attachment means  42  and the forward fasteners  44  are located. This also shows an accessory item fastener  43 , in this case a sheet metal screw, and a receptacle member  42  that is inserted into an opening in the accessory item  32 .  
     [0055] It is important to note that the “A” dimension noted here is critical to meet the width and shape of virtually all pickup truck tailgates. The “A” dimension extends from the forward surface of the tailgate to where a fastener is inserted into an upper surface of the tailgate. The “A” dimension can range between three-fourth to one and one-half inches inch aft of the front surface of the tailgate with a range of one to one and one-fourth inches a preferred range.  
     [0056] The “B” dimension is also important as it was established to also work on virtually all pickup truck tailgates. Both the “A” and “B” dimensions account for different shapes and thickness of tailgates. The “B” dimension extends from an upper surface of the tailgate adjacent a forward fastener  44 . The “B” dimension is defined as being at least one inch with one and one-fourth preferred below an upper surface of the tailgate proximal a forward fastener  44 .  
     [0057]FIG. 10 presents the same cross-sectional view as did FIG. 9 except for two noted items. First, the accessory item attachment means  42  incorporates a fastening means as part of its structure and also offers a seal  45 , in this case an O-ring, that both makes of a more secure connection and also resists moisture penetration into the accessory item. Second, there is a cargo bedliner  41  positioned on the forward side of the tailgate  38 . It is important to note that, even with the bedliner  41  in place, the “A” dimension still falls into the same dimensional ranges as given in the preceding discussion about FIG. 9.  
     [0058]FIG. 11 presents similar views and components as FIGS. 9 and 10 except it is based on FIGS. 7 and 8 where the positioning device  36  has been maintained in place.  
     [0059]FIG. 12 offers an alternative installation method to that given in FIG. 11 whereby the positioning device  36  has the accessory item attachment means  42  attached directly to it by a fastener  49 . It is to be realized that other means such as swaging, welding, etc. can be used to fasten the accessory item attachment means  42  to the positioning device  36 . A separate upper fastener  48  is, in this preferred embodiment of this variation of the instant invention, used to aid in attaching the positioning fixture to the tailgate  38 . It is important that the positioning of the upper fastener(s)  48 , per noted dimension “A”, can range between three-fourth to one and one-half inches inch aft of the front surface of the tailgate with a range of one to one and one-fourth inches a preferred range.  
     [0060] An advantage to the inventive approaches presented in FIGS. 11 and 12 are that they make for easier more “idiot proof” installations. This is because, since the positioning device  36  remains on the tailgate  38 , a novice installer does not have to do any critical locating of fasteners, etc.  
     [0061] A valuable feature of the preferred embodiment of the attachment means  42  shown in FIGS. 9, 10,  11 , and  12  is that they are all blind. In these preferred embodiments, there is no direct fastener, such as a screw fastener, that attaches the attachment means  42  to the accessory item  32 . The attachment means  42  simply fits into an opening in the accessory item that includes, in these examples, an insert  46 . The attachment means  42 , whether blind or not, takes at least a majority of the torque forces applied to the tailgate  38  when closing it by applying a lifting force to the accessory item  32 . In the ideal case of the instant invention, there is no fastener directly attaching the accessory item  32  to the top of the tailgate  38 .  
     [0062] While the invention has been described in connection with a preferred and several alternative embodiments, it will be understood that there is no intention to thereby limit the invention. On the contrary, there is intended to be covered all alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims, which are the sole definition of the invention.