Patent Description:
Vehicles equipped with cargo beds (<CIT>) are useful in situations requiring significant hauling capacity. Cargo beds are commonly designed as large, flat beds enclosed by side walls and a rear tailgate that may open to allow easier loading of contents, and close to help secure the contents within the bed during vehicle operation. Various tailgate designs exist. For example, some tailgates are designed to pivot about an axis at or proximate to the lower end of the tailgate panel, resulting in a small gap between the open tailgate and the bed. Conversely, some tailgates are designed with components such as wide-throw or swing-clear hinges that leave an offset or gap between the tailgate panel and the end of the cargo bed, effectively extending the useful length of the cargo bed when the tailgate is open. This often entails an additional tailgate component, such as a sill flap, that covers the gap when the tailgate is open. Such tailgate designs also present challenges, however. For example, space constraints under the vehicle bed, and the sizes and shapes of various vehicle components located there, may dictate unconventional bed shapes that may present difficulties in designing compatible sill flaps.

Accordingly, systems and methods are disclosed herein that provide a vehicle tailgate assembly that allows, for example, the spare tire bin to extend beyond the tailgate sill flap in the closed position, while still allowing the sill flap to open and close properly. In some embodiments, the tailgate assembly includes both a tailgate and a sill flap, where the sill flap has a cutout to accommodate a portion of the spare tire bin when the sill flap is folded down into its open configuration. The tailgate opens away from the truck bed to leave a gap or space between the edge of the bad and the tailgate when opened. The sill flap opens to fit within this space, so that the tailgate and sill flap, when in the open configuration, both lie flat to act as an extension of the vehicle bed.

As the assembly includes both a sill flap and tailgate, the sill flap has a number of rollers located at its upper edge and facing the tailgate, where the rollers contact the tailgate when the tailgate and sill flap are opened. Thus, when opened, the rollers of the sill flap roll along the inner surface of the tailgate as the sill flap and tailgate are pivoted from their upright closed configuration to their horizontal opened configuration. That is, the sill flap lies on the tailgate as the tailgate assembly is opened, with the sill flap rollers preventing sliding contact between the sill flap and tailgate. In particular, the rollers of the sill flap rotatably contact the tailgate to roll as the sill flap and tailgate move relative to each other, preventing scraping or other friction damage between the sill flap and tailgate when the tailgate assembly is opened or closed.

In some embodiments, raised or recessed channels are formed in the tailgate, to accommodate the rollers when they roll along the tailgate. Thus, the sill flap is arranged to place the rollers within or upon the channels, with the rollers rotatably contacting the channels as the tailgate assembly is opened/closed. In some embodiments, the rollers may not contact the channels when the tailgate assembly is fully opened. Instead, a lip of the sill flap may rest on, and be supported by, a portion of the tailgate.

As above, the sill flap may incorporate a cutout to accommodate any portion of the spare tire bin or other element of the vehicle bed. The cutout may be of any shape suitable for accommodating any portion of the vehicle bed. Accordingly, the sill flap may be narrower along its cutout, and wider elsewhere. Such configuration allows a portion of the vehicle bed to extend beyond the sill flap when the sill flap is closed.

The sill flap may be connected to the vehicle bed in any manner. For example, the sill flap may be connected to the vehicle bed via one or more hinges. Hinges may be configured in any manner, such as with a torsion spring whose opposing ends are connected to the sill flap and vehicle bed respectively.

In this manner, embodiments of the disclosure provide a sill flap and tailgate each pivotably connected to a vehicle bed, where the sill flap has one or more rollers facing the tailgate. The rollers thus rotate along the tailgate while the sill flap and the tailgate are pivoted between a closed vehicle bed orientation and an open vehicle bed orientation.

US patent documents <CIT>, <CIT> and <CIT> may assist in understanding the invention.

In one embodiment, the disclosure relates to a vehicle tailgate assembly that includes a sill flap and tailgate, where the sill flap has rollers that contact the tailgate while the sill flap and tailgate are opened or closed. The sill flap thus maintains rolling contact with the tailgate during opening and closing operations. In embodiments of the disclosure, the tailgate opens to leave a gap between the edge of the vehicle bed and the edge of the tailgate, where the sill flap is pivoted into this gap. While being pivoted into this open position, the sill flap rollers rotatably contact the tailgate, so that the sill flap maintains rolling contact with the tailgate rather than frictional contact therewith. This prevents damage to the sill flap and tailgate when opened and closed. Such configurations also allow for various sill flap shapes, including those with cutouts accommodating various vehicle bed shapes. In this manner, sill flaps may accommodate many different bed designs and shapes.

Configurations of embodiments of the disclosure thus provide a tailgate assembly in which both the tailgate and the sill flap open to a horizontal configuration, providing greater extension of the vehicle bed when opened. The sill flap may also have a cutout accommodating a portion of the tire bin when the tailgate assembly is closed, thus allowing the tire bin to extend beyond the tailgate when closed, and accordingly allowing more space to accommodate various vehicle components under the bed.

<FIG> is an isometric view of an electric vehicle bed and tailgate assembly constructed in accordance with some embodiments of the disclosure. Here, a vehicle tailgate assembly <NUM> includes a sill flap <NUM> shown in its closed configuration, and a tailgate <NUM> shown in its open configuration. The sill flap <NUM> and tailgate <NUM> are each pivotably affixed to the end <NUM> of a vehicle bed <NUM>, as shown. The sill flap <NUM> is affixed to the vehicle bed <NUM> by hinges <NUM> at its bottom end. Thus, the sill flap <NUM> is oriented vertically in the view of <FIG> when the tailgate assembly <NUM> is closed, i.e., when the vehicle bed <NUM> is closed. The tailgate <NUM> is likewise oriented vertically when the tailgate assembly <NUM> is closed, so that the tailgate <NUM> and sill flap <NUM> are both arranged vertically and generally parallel to each other. When the tailgate assembly <NUM> is opened, i.e., when the vehicle bed <NUM> is open, the tailgate <NUM> lies flat or horizontal in the view of <FIG>, and the sill flap <NUM> pivots upon its hinges <NUM> to lie flat between the end <NUM> of the vehicle bed <NUM> and the tailgate <NUM>. In this manner, both the sill flap <NUM> and the tailgate <NUM>, when in their open configuration, are positioned as extensions of the vehicle bed <NUM>, serving as portions of the bed load floor surface and providing a larger vehicle bed area.

Rollers <NUM> are positioned at or near the upper edge of the sill flap <NUM> to face the tailgate <NUM> when the tailgate <NUM> and sill flap <NUM> are in their closed configuration. The surface of tailgate <NUM> facing the sill flap <NUM> (when both the sill flap <NUM> and tailgate <NUM> are in the closed configuration) has a number of raised channels <NUM> and recessed channels <NUM> formed therein and positioned to accept the rollers <NUM> when the sill flap <NUM> and tailgate <NUM> face each other. In this manner, when the tailgate assembly <NUM> is opened, both the sill flap <NUM> and tailgate <NUM> fold downward from their vertical orientation to their horizontal orientation, with the sill flap <NUM> lying against the tailgate <NUM> as both are pivoted into their horizontal orientations. To prevent frictional contact during opening, the sill flap <NUM> contacts the tailgate <NUM> at its rollers <NUM>, with the rollers <NUM> rotatably moving along the raised channels <NUM> as the sill flap <NUM> moves relative to tailgate <NUM>. As the tailgate assembly <NUM> is fully opened, rollers <NUM> are seated within recessed channels <NUM>, where they are maintained while the tailgate <NUM> and sill flap <NUM> are in their fully open positions. In some embodiments, the lip of sill flap <NUM> rests on a recessed ledge of the tailgate <NUM> in their open positions. In some embodiments, the bottoms of rollers <NUM> are positioned within recessed channels <NUM>, but do not make contact with the bottom of the recessed channels or do not bear significant weight when the sill flap <NUM> is in its open position. This way, the full amount or a significant amount of the weight of any objects resting on sill flap <NUM> is supported across the lip of the sill flap <NUM>. In some embodiments, this provides a larger contact area for supporting the weight and prevents large forces on the rollers <NUM>.

The sill flap <NUM> has a cutout <NUM> in its lower edge, proximate to the hinges <NUM>, where this cutout <NUM> is shaped to accommodate the curved end <NUM> of the vehicle bed <NUM> when the sill flap <NUM> is folded down to its open configuration. In this manner, embodiments of the disclosure allow for larger vehicle beds whose ends <NUM> may protrude beyond the sill flap <NUM> when the sill flap <NUM> is closed, providing greater clearance for other vehicle components. For example, vehicles may be provided greater clearance for tire bins that must accommodate larger tires. As another example, electric vehicles may be provided greater clearance under their cargo beds to accommodate larger battery packs or other electrical components. Furthermore, various shapes of components such as spare tires can be accommodated, such as shown in <FIG> where a curved portion of the spare tire bin extends past sill flap <NUM>, and cutout <NUM> is thus shaped to accommodate the curved spare tire bin.

<FIG> is a top view illustrating further details of an electric vehicle bed and tailgate assembly constructed in accordance with some embodiments of the disclosure. As shown, each roller <NUM> of sill flap <NUM> is positioned to roll along a raised channel <NUM> when the sill flap <NUM> and tailgate <NUM> are opened, with the rollers <NUM> rolling from the raised channels <NUM> into recessed channels <NUM> when the sill flap <NUM> and tailgate <NUM> are placed in their fully open configuration. In this manner, when fully opened, the sill flap <NUM> lies horizontal, or substantially parallel to the upper surface of the vehicle bed <NUM>, to be positioned between the end <NUM> of the vehicle bed <NUM> and the edge of the tailgate <NUM>.

<FIG> is an isolation view of a sill flap of a tailgate assembly constructed in accordance with some embodiments of the disclosure. In particular, <FIG> shows the surface of sill flap <NUM> that faces tailgate <NUM>. As can be seen, sill flap <NUM> rotates about hinges <NUM> to pivot between closed and open configurations, with rollers <NUM> contacting the surface of tailgate <NUM> that faces sill flap <NUM>, and more specifically contacting the raised channels <NUM> of tailgate <NUM>. Any number of hinges <NUM> may be employed to pivotably connect the sill flap <NUM> to the vehicle bed <NUM>. Furthermore, the cutout <NUM>, while being shown as generally arcuate to correspond to the shape of the end <NUM> of the vehicle bed <NUM>, may be of any suitable and desired shape.

Sill flap <NUM> and tailgate <NUM> may be constructed of any suitable material or materials. For example, sill flap <NUM> and tailgate <NUM> may each be made of steel, aluminum, an ultraviolet (UV) light resistant sheet molded compound (SMC), or any other material suitable for construction of a vehicle tailgate assembly.

<FIG> is a view illustrating further details of a tailgate assembly constructed in accordance with some embodiments of the disclosure. As above, the tailgate <NUM> is shown in its opened configuration, positioned to lie horizontally or generally parallel to the upper surface of the vehicle bed <NUM>. Sill flap <NUM> is not depicted in <FIG> so that the underlying structure is visible. When opened, the rollers <NUM> of sill flap <NUM> roll along raised channels <NUM> to land within recessed channels <NUM> when the tailgate assembly <NUM> is fully opened.

<FIG> is an isometric view illustrating further details of the sill flap rollers <NUM> in accordance with some embodiments of the disclosure. The rollers <NUM> may be any rotatable elements suitable for maintaining rolling contact with tailgate <NUM>. In some embodiments, each roller <NUM> is rotatably affixed to a bracket <NUM> for attachment to sill flap <NUM>. In particular, bracket <NUM> has any number of flanges <NUM> extending therefrom and having holes or other features accommodating fasteners <NUM> that rigidly affix brackets <NUM> to corresponding features (e.g., holes, flanges, or the like) of sill flap <NUM>. The fasteners <NUM> may be any fasteners suitable for rigidly affixing brackets <NUM> and rollers <NUM> to sill flap <NUM>, such as screws, bolts, rivets, or the like. In this manner, rollers <NUM> are rotatably coupled to the sill flap <NUM> and positioned to face the tailgate <NUM> so as to roll on raised channels <NUM> and drop within recessed channels <NUM> when the tailgate assembly <NUM> is opened or closed.

The brackets <NUM> and flanges <NUM> may be made of any material suitable for rigidly affixing one or more components of rollers <NUM> to a sill flap <NUM>, such as a steel, an aluminum, SMC, or the like. Furthermore, rollers <NUM> may be made of any material suitable for allowing rolling contact with tailgate <NUM> without excessive wear on either rollers <NUM> or tailgate <NUM>. For example, rollers <NUM> may be made of a plastic such as a polyurethane, a metal such a steel or an aluminum, or any other suitable material.

<FIG> is a cutaway side view of a tailgate assembly constructed in accordance with some embodiments of the disclosure. More specifically, <FIG> illustrates the closed configuration of sill flap <NUM> and tailgate <NUM>. Here, sill flap <NUM> and tailgate <NUM> are closed, each oriented substantially vertically with respect to the vehicle bed <NUM> and positioned generally parallel to each other. In some embodiments, in the closed configuration, sill flap <NUM> and tailgate <NUM> are in contact with each other, with rollers <NUM> lying on the upper portions of the raised channels <NUM>. The tailgate <NUM> may have any cross-sectional structure, such as the structure shown in <FIG>. In some embodiments, in the closed configuration, sill flap <NUM> and tailgate <NUM> are in contact with each other, with rollers <NUM> positioned beyond the ends of raised channels <NUM>. In this configuration, sill flap <NUM> and tailgate <NUM> may achieve closer positioning with respect to each other in the closed configuration. In addition, in this configuration, the contact area between the sill flap <NUM> and the tailgate <NUM> may be increased, which provides a larger contact area for supporting lateral forces. Transition from the closed configuration of <FIG> to the open configuration is further described below in connection with <FIG>.

<FIG> is an isometric view illustrating further details of a sill flap hinge assembly constructed in accordance with some embodiments of the disclosure. As above, each hinge <NUM> allows sill flap <NUM> to pivot between its closed or vertical configuration and its open or horizontal configuration. Each hinge <NUM> may include a first panel <NUM> affixed to sill flap <NUM>, a second panel <NUM> affixed to the vehicle bed <NUM>, and a torsion spring <NUM> with a first end <NUM> and an opposing second end <NUM>. The first panel <NUM> and second panel <NUM> are connected in any rigid manner to sill flap <NUM> and the vehicle bed <NUM> respectively. For example, each may be connected by any fasteners, adhesives, snap fit joints, or the like. Similarly, the ends <NUM>, <NUM> of each torsion spring may be connected in any rigid manner to first panel <NUM> and second panel <NUM> respectively. For instance, ends <NUM>, <NUM> may be connected to panels <NUM>, <NUM> by any welding or soldering, by inserting or pressing ends <NUM>, <NUM> into corresponding features of panels <NUM>, <NUM>, or the like. In operation, the torsion spring <NUM> of each hinge <NUM> is placed in torsion when the sill flap <NUM> is closed, providing a force that acts to press the sill flap <NUM> against the tailgate <NUM> in the closed configuration and during opening and closing of the sill flap <NUM> and tailgate <NUM>.

Movement of the tailgate assembly <NUM> from its closed configuration to its open configuration is now described in further detail in conjunction with <FIG>. <FIG> is an isometric cutaway view illustrating further details of open and closed configurations of a tailgate assembly <NUM> constructed in accordance with some embodiments of the disclosure, and <FIG> is a cutaway view illustrating further details of contact between the sill flap rollers <NUM> and tailgate <NUM>, in accordance with some embodiments of the disclosure. As can be seen in the view of <FIG>, when the sill flap <NUM> and tailgate <NUM> are closed, they are each oriented substantially vertically with respect to the vehicle bed <NUM>, with the sill flap <NUM> positioned against the surface of tailgate so that rollers <NUM> may contact tailgate <NUM>. In some embodiments, rollers <NUM> are the only components of sill flap <NUM> to contact tailgate <NUM>, however, this need not necessarily be the case in the closed configuration (e.g., in the configuration where the rollers <NUM> are positioned beyond the ends of raised channels <NUM>).

The sill flap <NUM> and tailgate <NUM> may then be opened. When opened, tailgate <NUM> pivots outward and away from the edge <NUM> of the vehicle bed <NUM> as shown in the leftmost portion of <FIG> and in <FIG>, such as via one or more gooseneck hinges or other wide-throw or swingclear hinges. In this position, a gap or space is formed between the tailgate <NUM> and the edge <NUM> of the vehicle bed <NUM>. The sill flap <NUM> pivots downward into this gap, to be placed between the tailgate <NUM> and edge <NUM> as shown in <FIG>. When the sill flap <NUM> and tailgate <NUM> are moved from their closed to their open configurations, the sill flap <NUM> may be maintained against the tailgate <NUM> so that rollers <NUM> contact the tailgate <NUM>. When such contact is maintained, the rollers <NUM> rotatably contact the raised channels <NUM> of tailgate <NUM> to roll along raised channels <NUM> and into recessed channels <NUM>, where they may be maintained while the sill flap <NUM> and tailgate <NUM> are in their fully open configuration. In some embodiments, rollers <NUM> are the only points of contact between sill flap <NUM> and tailgate <NUM> when the tailgate assembly <NUM> is moved between its closed and open configurations. Accordingly, rollers <NUM> prevent sliding friction between the sill flap <NUM> and tailgate <NUM>, instead allowing for rotational contact between the two. This prevents friction and thus excessive wear on the tailgate assembly <NUM>. While rollers <NUM> are shown as being in contact with the recessed channels <NUM> of tailgate <NUM> when the sill flap <NUM> and tailgate are in their fully open configuration, this need not necessarily be the case, and embodiments of the disclosure contemplate configurations in which the rollers <NUM> do not maintain contact with the recessed channels <NUM> when the tailgate <NUM> and sill flap <NUM> are fully open. That is, in some embodiments, the rollers <NUM> may for example be sized and positioned to lose contact with the upper surface of tailgate <NUM> when they roll off the end of raised channels <NUM> and over (or into) recessed channels <NUM>. Recessed channels <NUM> may also have a depth greater than the diameter of rollers <NUM>, so that rollers <NUM> do not contact channels <NUM> when the lip of sill flap <NUM> is in contact with the ledge of tailgate <NUM>. In such embodiments, the upper edge of sill flap <NUM> may be the only contact between the sill flap <NUM> and tailgate <NUM> in the fully open position.

It is also noted that, in some embodiments of the disclosure, tailgate <NUM> may be formed with a ledge or flat area between the ends of raised channels <NUM> and recessed channels <NUM>, to provide an area or line of contact with the lip of sill flap <NUM> when the tailgate <NUM> and sill flap <NUM> are fully opened. As above, this provides a support for sill flap <NUM> to rest upon, preventing excessive stresses and damage to sill flap <NUM> when loads are placed thereon. Additionally, the ends of raised channels <NUM> and recessed channels <NUM> may have any slope or angle, to provide a more gradual path for rollers <NUM> as they are rolled between raised channels <NUM> and recessed channels <NUM>. This in turn prevents damage to rollers <NUM> and tailgate <NUM> during opening and closing operations.

<FIG> is an isometric view of a vehicle bed spare tire bin and spare tire in accordance with some embodiments of the disclosure, and <FIG> is an isometric view illustrating further details of the spare tire bin of <FIG>. In particular, the vehicle bed <NUM> may include a spare tire bin <NUM> sized and shaped to store a spare tire <NUM> within, with a curved edge <NUM> for accommodating the shape of spare tire <NUM>. In some embodiments of the disclosure, it may be desirable for a portion of the spare tire bin <NUM> to extend beyond the sill flap <NUM> in the closed position, providing increased space or clearance within the vehicle. This in turn allows embodiments of the disclosure more space under vehicle beds, to accommodate various components. For instance, this allows electric vehicles to accommodate larger battery packs or components under their vehicle beds.

Embodiments of the disclosure contemplate sill flap <NUM> configurations that may be different from those shown above. As one example, cutouts <NUM> may be of any size, shape, and number suitable for accommodating any shape and configuration of edges <NUM>. As another example, sill flap <NUM> may have any number of hinges <NUM> located at any positions along sill flap <NUM>. The hinges <NUM> may have any configuration allowing for pivotable attachment to vehicle bed <NUM>, using any mechanism besides a torsion spring, such as a shock and/or damper, a flexible member for absorbing rotational energy of the sill flap <NUM>, or the like.

Claim 1:
A vehicle tailgate assembly, the tailgate assembly comprising:
a sill flap (<NUM>) having a first end for connection to a vehicle bed (<NUM>), a second end opposite the first end, and one or more rollers (<NUM>) rotatably coupled to the second end; and
a tailgate (<NUM>) configured for coupling to the vehicle bed,
characterised in that:
the sill flap (<NUM>) and the tailgate (<NUM>) are configured to pivot between a closed vehicle bed configuration having the sill flap (<NUM>) oriented substantially parallel to the tailgate (<NUM>) with the one or more rollers (<NUM>) positioned between the sill flap (<NUM>) and the tailgate (<NUM>), and an open vehicle bed configuration in which upper surfaces of both the sill flap (<NUM>) and the tailgate (<NUM>) are oriented substantially parallel with an upper surface of the vehicle bed (<NUM>) with at least a portion of the sill flap (<NUM>) positioned upon the tailgate (<NUM>).