Patent Abstract:
An insert and a tailgate cable assembly incorporating the same. The tailgate cable assembly is a cable having eyelet connectors at each end and which is used to secure the sidewall of a vehicle to a rotatable tailgate. Fasteners extending from the sidewall and tailgate are received through apertures in the eyelets. At least one of the eyelets incorporates a removable insert that is rotatable between a first position, where the fastener may be either inserted or withdrawn from the eyelet, and a second position where the insert locks the fastener within the aperture in the eyelet. The insert is a “C”-shaped member that interlocks with the eyelet&#39;s interior peripheral surface surrounding a portion of the aperture.

Full Description:
BACKGROUND OF THE INVENTION 
     1. Technical Field 
     This invention generally relates to mechanisms for supporting vehicle tailgates. More particularly, the invention relates to an insert and cable assembly for supporting a tailgate when in a substantially horizontal open position. Specifically, the invention relates to an insert that interlocks with an eyelet disposed at one end of a cable, the insert being selectively rotatable within the eyelet to secure the eyelet to a fastener extending from the vehicle sidewall or tailgate. 
     2. Background Information 
     Many vehicles, such as pickup trucks, are provided with tailgates that may be swung between open and closed positions. When the tailgate is in the closed position, it is substantially vertically oriented with respect to the vehicle bed floor and a load held on the bed is prevented from sliding off the vehicle and into the road. When the user wishes to unload goods carried on the vehicle, the tailgate is lowered into a substantially horizontal open position, thereby providing easier access to the load. 
     Tailgates are typically supported in the open position by a pair of coated, flexible steel cables that are each connected at a first end to the vehicle sidewall and at a second end to one side of the tailgate. The cables are connected to the sidewall and tailgate by way of fasteners which are inserted through eyelets extending outwardly from the first and second ends of the cable. It is common for the two eyelet connectors to be dissimilar in shape. The tailgate eyelet connector typically is generally “O”-shaped with a centrally located circular hole formed therein. The sidewall eyelet connector may be generally elliptical in shape with a keyhole-shaped aperture formed therein. A spring-biased, substantially rectangular plate is clamped around the base of the sidewall eyelet and extends partially into the aperture. The fasteners for securing the eyelets to the vehicle may be bolts, rivets, pins and screws or any other suitable connector device. The shaft of the fastener received through the tailgate eyelet connector is of substantially the same size as the centrally-located hole. Consequently, very little rattling noise is produced by that connection when the vehicle is moving. A rattle is, however, frequently generated at the connection between the sidewall and the sidewall eyelet connector. The fastener used for this connection has a head portion with a diameter that is smaller than the wider portion of the keyhole-shaped aperture but is larger than the narrower portion of the aperture. The spring-biased plate extends into the wider portion of the aperture and toward the narrower portion of the aperture. The fastener is inserted into the wider portion of the aperture by pushing the plate out of the way either with the head of the fastener or with a screwdriver or similar device. The eyelet is then moved relative to the fastener so that the shaft of the fastener slides into the narrower portion of the aperture. The plate springs back into its initial position, thereby clamping the fastener and eyelet together. The diameter of the shaft of the fastener is typically less than the diameter of the narrower portion of the aperture. Consequently, when the vehicle is moving, there is movement between the eyelet and the fastener shaft and a rattling noise is generated. In addition to this problem, the plate tends to contribute to the corrosion of the eyelets because it is usually made from a dissimilar metal and tends to set up a galvanic corrosion cell. Additionally, it is common for users to remove the tailgate altogether so that they can either load or unload a particularly heavy item from the vehicle bed or carry a heavy item on the bed floor. The above-described sidewall eyelet connector is not particularly easy to release and frequently requires that a screwdriver or similar tool be used to force the plate out of engagement with the fastener. This can make the removal of the tailgate more difficult. 
     There is therefore a need in the art for a cable assembly that may be connected to both the sidewall and tailgate quickly and easily. There is furthermore a need for a cable assembly that does not rattle when the vehicle is moving and has a decreased tendency to rust. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to an insert that may be used in tailgate cable assemblies and to a tailgate cable assembly incorporating the same. The tailgate cable assembly is an elongated, flexible cable that has eyelet connectors at each end and which is used to secure a rotatable tailgate to the sidewall of a vehicle. Fasteners extending from the sidewall and tailgate are received through apertures in the eyelets. At least one of the eyelets incorporates a removable insert that is rotatable between a first position, where the fastener may be either inserted or withdrawn from the eyelet, and a second position where the insert locks the fastener within the aperture in the eyelet. The insert is a “C”-shaped member that has a channel formed in a flange extending from its rear wall and a portion of the eyelet&#39;s interior peripheral surface surrounding the aperture is received within the channel and locks the C-shaped member and eyelet together. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The preferred embodiment of the invention, illustrative of the best mode in which applicant has contemplated applying the principles, is set forth in the following description and is shown in the drawings and is particularly and distinctly pointed out and set forth in the appended claims. 
         FIG. 1  is a side view of a vehicle with the tailgate in an open position showing the tailgate being supported by the cable assembly in accordance with the present invention; 
         FIG. 2  is an exploded perspective view of the sidewall eyelet connector end of the tailgate cable assembly; 
         FIG. 2A  is a rear elevational view of the sidewall connector with an insert received within a wider portion of the aperture; 
         FIG. 2B  is a rear elevational view of the sidewall connector with the insert being moved into the narrower portion of the aperture; 
         FIG. 2C  is a rear elevational view of the sidewall connector with the insert engaged with the base; 
         FIG. 3  is a perspective view of the sidewall connector in an open position; 
         FIG. 4  is a perspective view of the sidewall connector with the wider portion of the hole positioned over a fastener extending from the vehicle sidewall; 
         FIG. 5  is a front elevational view of the sidewall connector of  FIG. 4 ; 
         FIG. 6  is a cross-sectional side view of the sidewall connector through line  6 — 6 —of  FIG. 5 ; 
         FIG. 7  is a front elevational view of the sidewall connector with the fastener engaged in the narrower portion of the hole; 
         FIG. 8  is a cross-sectional side view of the sidewall connector through line  8 — 8 —of  FIG. 7 ; 
         FIG. 9  is a partial cross-sectional rear view of the sidewall connector through line  9 — 9  of  FIG. 8 ; 
         FIG. 10  is a front elevational view of the sidewall connector with the insert rotated into the locked position around the fastener; 
         FIG. 11  is a cross-sectional side view of the sidewall connector through line  11 — 11  of  FIG. 10 ; 
         FIG. 12  is a rear elevational view of the sidewall connector through line  12 — 12  of  FIG. 11 ; and 
         FIG. 13  is a cross-sectional left side view of the sidewall connector through line  13 — 13  of  FIG. 10 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to  FIGS. 1–3 , there is shown a vehicle  10  of the type having a bed with a floor  12 , sidewalls  14 ,  16  and a tailgate  18 . Tailgate  18  is mounted to vehicle  10  by way of rod ends  20  and is rotatable about rod ends  20  between a vertical position (not shown) and a horizontal position ( FIG. 1 ). Tailgate  20  and supports  22  on sidewalls  14 ,  16  are connected together by a pair of cable assemblies  24  that assist in supporting tailgate  20  when it is in the horizontal, open position. Only one of the cable assemblies  24  is illustrated in  FIG. 1  and described below for the sake of clarity. It will be understood, however, that the two cable assemblies are substantially identical. 
     Cable assembly  24  comprises an elongated, flexible steel cable  26  having a tailgate connector  28  secured to a first end thereof and a sidewall connector  30  secured to a second end thereof. Tailgate connector  28  is of the type commonly used in the industry, being a substantially circular eyelet with a central hole therein and is secured to the tailgate by a suitable fastener inserted through the central hole. Sidewall connector  30  ( FIGS. 2&amp;3 ) comprises a base  32  having a shaft  34  extending outwardly therefrom. Shaft  34  includes a pair of flanges  36  that are crimped around cable  26  to secure connector  30  thereto. Base  32  has a substantially keyhole-shaped aperture  38  formed therein and aperture  38  has a wider portion  38   a  and a narrower portion  38   b . The maximum width “R” of portion  38   a  is greater than the maximum width “S” of portion  38   b . A lip portion  40  separates wider portion  38   a  from narrower portion  38   b . Base  32  has a thickness “T”. When viewed from the front, narrower portion  38   b  of base  32  is substantially C-shaped and has an arcuate interior peripheral surface  42 . 
     Referring to  FIGS. 2–6 , an insert  44 , in accordance with the present invention, is provided for engagement with base  32 . Insert  44  is manufactured from a rigid material preferably plastics such as acetal, polyester, nylon and filled nylon materials or metals compatible with those from which base  32  is manufactured. Insert  44  comprises a substantially C-shaped member with a front wall  46 , a rear wall  48 , an outer peripheral wall  50  and an interior opening  57 . Outer peripheral wall  50  of insert  44  preferably is ridged so as to provide a gripping surface for the fingers of a user. Front wall  46  of insert  44  includes a C-shaped groove  52  and a recessed fastener-engaging surface  54 . As may be seen from  FIGS. 2&amp;3 , both narrower portion  38   b  of aperture  38  and insert  44  are substantially C-shaped and have a substantially identical radius of curvature. A flange  56  extends outwardly from and normal to rear wall  48 . Flange  56  is generally C-shaped when viewed from the rear, has an interior surface  58 , an exterior surface  60  and a chamfered lip  62 . Interior surface  58  of flange  56  defines an interior opening  57  within insert  44 . An U-shaped channel  64  ( FIG. 6 ) is formed between lip  62  and rear wall  48  of insert  44 . The width of channel  64  is substantially equal to the width “T” of base  32 . As may be most easily seen in  FIG. 5 , the leading edges  66  of groove  52  and surface  54  are angled to guide a fastener  68  toward the interior surface  58  of flange  56 . 
     Referring to  FIGS. 2 through 2C , insert  44  is engaged with sidewall connector  30  in the following manner. Flange  56  of insert  44  is inserted into the wider portion  38   a  of aperture  38  in base  32  and is moved in the direction of arrow “A” ( FIG. 2 ) until the rear wall  48  of insert  44  rests on the front surface  32   a  of base  32 . The initial orientation of insert  44  relative to base  32  is not critical because the component is twisted slightly as it is slid along base  32  and into narrower portion  38   b  of aperture  38 . So, for example, insert  44  may be oriented as shown in  FIG. 2  or as it is shown in  FIG. 2A  or in any other orientation that will bring rear surface  48  into contact with front surface  32   a  of base  32 . Insert  44  is then moved in the direction of arrow “B” ( FIG. 2B ) until flange  56  is received in narrower portion  38   b  of aperture  38 . Insert  44  is twisted to cause chamfered lip  62  on flange  56  to ride over rear surface  32   b  of base  32 . Insert  44  is simultaneously twisted and moved in the direction of arrow “B” until the interior surface  42  of base  32  is received within the channel  64  of insert  44  and abuts exterior surface  60  of flange  56  ( FIGS. 2&amp; 6 ). Flange  56  frictionally engages base  32  to retain insert  44  on base  32 . Once insert  44  is retained on base  32 , cable assembly  24  is ready to be connected to support  22  and insert  44  is in a first position where it is able to receive a fastener  68  therein. The portion of base  32  that surrounds narrower portion  38   a  of aperture  38  and onto which insert  44  is engaged, is substantially flat (see  FIG. 6 ) and insert  44  is rotatable on this substantially flat portion of base  32  as will be hereinafter described. 
     Fastener  68  comprises a head  68   a , a body  68   b  and a shaft  68   c . Fastener  68  is mounted to support  22  via washers  70 ,  71  and nut  72  to support  22 . Body  68   b  of fastener  68  has a height “V” which is substantially the same as the width “W” of flange  56  of insert  44  ( FIG. 6 ). The diameter “X” of body  68   b  of fastener  68 ( FIG. 5 ) is substantially the same as the width “Y” of opening  57  formed by interior surface  58  of flange  56 . Head  68   a  of fastener  68  has a diameter “X” that is greater than the diameter “Y” of interior surface  58  of insert  44 , but is less than the diameter “Z” of groove  52  of insert  44 . The height “J” of head  68   a  of fastener  68  may be less than, equal to or greater than the depth “K” of groove  52 . When fastener  68  is mounted to support  22 , it extends outwardly from a front surface  22   a  of support and is disposed substantially at right angles thereto. 
     Referring to  FIGS. 4–13 , cable assembly  24  may be secured to fastener  68  in the following manner. Sidewall connector  30  of cable assembly  24  is brought into the proximity of fastener  68  and is moved in the direction of arrow “C” ( FIG. 4 ) so that fastener  68  enters wider portion  38   a  of aperture  38 . The user grasps cable  26  and pulls the same in the direction of arrow “D” ( FIG. 5 ) so that base  32  slides laterally with respect to washer  70 . This lateral movement causes base  32  to slide past fastener  68  so that body  68   b  of fastener  68  enters narrower portion  32   b  of base  32 . Continued movement of cable  26  in the direction of arrow “D” causes body  68   b  to slide between leading edges  66  of insert  44  and toward interior surface  58  of flange  56 . The lateral movement causes the lower surface  74  of head  68   a  to ride over fastener engaging surface  54  of insert  44 . Ultimately, the outer surface  76  of body  68   b  abuts the interior surface  58  of flange  56  ( FIGS. 7&amp;8 ). The relative sizes of the body  68   b  and insert  44  causes the sidewall connector  30  to be wedged between lower surface  74  of head and washer  70 . However, fastener  68  is not locked within sidewall connector  30  and the two components may be disengaged from each other by pushing cable  26  in the opposite direction to arrow “D”. In order to lock fastener  68  and sidewall connector  30  together, insert  44  must be rotated in the direction of either arrow “E” or arrow “F” ( FIG. 7 ) until insert  44  is disposed in the position indicated in  FIGS. 10–13 . Insert  44  rotates about an axis Q–Q′ ( FIG. 8 ) that lies substantially at ninety degrees to the flat portion of base  32  surrounding narrower portion  38   b  of aperture  38 . In this position, insert  44  prevents fastener  68  from being removed from aperture  38 . Furthermore sidewall connector  30  is prevented from moving laterally in the direction of arrow “D” or in the opposite direction thereto, but is free to rotate around fastener  68  as is indicated by the arrow in  FIG. 10 . 
     Insert  44  may be provided as a retrofit component for cable assemblies known in the prior art that are presently manufactured with a spring-biased plate (not shown) extending into the wider portion the aperture in the base. In order to retrofit such known cable assemblies with insert  44 , the spring-biased plate would be removed from the base and the insert  44  could then be connected into the base  32  in the manner described above with respect to the cable assembly in accordance with the present invention. Alternatively, a cable assembly in accordance with the present invention may be manufactured and then sold with the insert  44  engaged with the base  32 . 
     The tailgate connector  28  of the cable assembly  24  may be substantially identical to the tailgate connector of cable assemblies known in the prior art and may furthermore be connected to the tailgate of a vehicle in the same manner as previously known tailgate connectors. However, it will be understood that the tailgate connector  28  of the present invention may be of substantially identical structure and function as the sidewall connector  30  as herein disclosed. 
     When cable assembly  24  is connected between tailgate  18  and support  22  and tailgate  18  is in the open position, cable  26  is in tension and interior peripheral surface  42  of base  32  lies in direction contact with fastener  68 . Insert  44  does not bear any significant load when cable  26  is in tension. The only load borne by insert  44  is equal to the column strength of cable  26  itself. When tailgate  18  is in a closed position, cable  26  is no longer under tension and insert  44  again does not bear any significant load. 
     It will further be understood that while fastener engaging surface  54  is disposed a distance inwardly of front wall  46  of insert  44 , surface  54  and front wall  46  may be coplanar with each other. Front wall  46  is provided a distance outwardly from surface  54  so that outer peripheral wall  50  of insert  44  has some depth for easy of rotating insert  44  between its open and closed positions. Insert  44  is designed to be eccentric to the centerline of fastener  68 . This provides minimal clearance between fastener  68  and the rotated insert  44  to substantially prevent movement and subsequent rattle of the installed assembly. 
     Furthermore, while insert  44  is shown in use on a sidewall connector  30  having a keyhole-shaped aperture  38  therein, it will be understood that insert  44  may be used on a sidewall connector having a differently shaped aperture therein. Insert  44  would be engaged with the base of the sidewall connector in the manner as described above and would then be utilized to define a region within that differently shaped aperture that would be substantially the same diameter as the fastener body to which the sidewall connector is to be secured. 
     In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed. 
     Moreover, the description and illustration of the invention is an example and the invention is not limited to the exact details shown or described.

Technology Classification (CPC): 8