Patent Description:
Compression Limiters or rivet nuts are often used to help create a robust threaded fastener joint that would otherwise creep and loosen if a plastic panel would be compressed in a typical threaded fastener joint. Compression limiters and rivet nuts, however, add cost and complexity to a design and to the assembly process. Conventional designs and methods have used mechanical fasteners like compression limiters, and rivet nuts or/and brackets that may not be over molded.

These cause problems with packaging, space, cost, complexity and quality, etc..

Thus, it is an objective of the present invention to eliminate the need for compression limiters or rivet nuts to reduce complexity, reduce cost, reduce possibility of poor assembly, reduce assembly time, reduce weight, etc..

Another known problem is that tethers are often times used on items such as thermoplastic ("TP") Litigates, and attachments can add extra costs and assembly time and complexity. Some conventional designs use mechanical fasteners and brackets that do not get over molded.

Thus, it is an objective of the present invention to maintain the overmolding of bracket advantage, and maintain an open hole for tether routing to reduce complexity, reduce cost, reduce possibility of poor assembly, reduce assembly time, reduce weight, etc..

<CIT> discloses a vehicle tailgate structure comprising a first panel portion comprising a composite material and a second panel portion overmolded onto the first panel portion, the first and second panel portions forming together a body portion, a transverse beam and side beams connecting the transverse beam to the body portion, wherein the transverse beam comprises a hinge attachment portion configured to receive a hinge attachment part, wherein the first panel portion has a bent strip in the transverse beam, and wherein the bent strip is raised with respect to a remaining portion of the first panel portion.

<CIT> discloses an opening part of a motor vehicle comprising a reinforcing element extending at least partially along a main plane, intended to reinforce fasteners and the environment of a lock of the opening part, and an envelope made from plastic, comprising an inner part overmolded at least partially on an inner face of the reinforcing element. The reinforcing element comprises at least one orifice, and the envelope comprises at least one external part including a segment passing through said orifice and a covering part locally covering one edge of the orifice on an outer face of the reinforcing element.

The present invention eliminates the need for compression limiters or rivet nuts to reduce complexity, reduce cost, reduce possibility of poor assembly, reduce assembly time, reduce weight, etc..

This invention allows the overmolding of the bracket and maintains a lower cost fastener joint that does not require extra components or special components.

The injection mold protects and maintains an opening through the molding operation, and, optionally, through open to die tip tool direction, or through tool action such as a lifter, and this open surface is the mounting surface for items such as hinges, ball stud, bracket, etc..

Preferably, the bracket mounting surface is maintained through the over molding process.

In addition, according to the invention putting holes in metallic reinforcements for tether routing creates a more efficient design. Overmolding metallic brackets creates an efficient method of combining the bracket and molded panel; thus, overmolding the bracket and maintaining the hole for tether routing creates an even more efficient and cost-effective design.

Referring to <FIG> generally, there is illustrated an exemplary liftgate assembly indicated generally at <NUM>, including an overmold bracket with at least one mounting surface on the bracket and method for making same, in accordance with the present invention. There is provided at least one overmold bracket with at least one open mounting surface on the bracket. The open mounting surface on the bracket can provide for at least one thermoplastic liftgate hardware attachment.

<FIG> depict a cross section at a hinge area taken at C-C of <FIG>, e.g., at least one of a pair of oppositely-disposed hinge portions. By way non-limiting examples, a liftgate hinge, rear window hinge, etc..

<FIG> depicts a cross-section taken at B-B of <FIG> at a ball stud attachment, e.g., one of oppositely-disposed bottom corner regions of a rear window, with a ball stud attachment depicted generally at <NUM>.

Referring more particularly to <FIG>, there is provided overmold and maintaining of an open footprint for direct hardware attachment. One benefit is a lower cost liftgate. Generally, the present invention overmolds and maintains a predetermined open footprint. Typically, the overmold portion, indicated generally at <NUM> is provided and an open footprint maintained, indicated generally at <NUM>, for direct hardware attachment, indicated generally at <NUM>, e.g., hinge <NUM>, ball stud <NUM>, hat bracket, latch fasteners, and any other bracket-type mounting, without the added costs that would be associated with rivet nuts or compression limiters, which the present invention eliminates, in accordance with aspects of the present invention. Optionally, weld nuts <NUM> (e.g., see <FIG>) can be used as needed and included with the overmolding bracket sub assembly; the overmolded bracket sub-assembly indicated generally at <NUM>. Preferably, at least one aperture <NUM> is provided through at least one bracket <NUM>, e.g., that is a latch bracket such as indicated generally at <NUM>, and overmold indicated generally at <NUM>, for operably connecting at least one attachment <NUM>, e.g., hinge, ball stud, hat bracket, latch fastener, and any other bracket type mounting, without the added cost of rivet nuts or compression limiters, and/or operably connecting at least one attachment that is a tether <NUM>, etc. The at least one aperture <NUM> can, by way of non-limiting example, be an opening. The at least one aperture <NUM> can by way of non-limiting example, be a hole.

Referring generally to <FIG>, according to aspects of the present invention, at least one injection mold protects and maintains the at least one aperture <NUM> throughout the molding operation, e.g., at least one liftgate panel <NUM> molding, and, preferably, through open to die tip tool direction, or through a tool action such as a lifter, or any other suitable process, and this open surface is the mounting surface for items such as hinges, ball stud, bracket, etc. and any combinations thereof. The present invention operably maintains the predetermined bracket mounting surface through the predetermined over molding process.

The present invention allows the overmolding of the at least one bracket <NUM> and maintains a lower cost fastener joint that does not require extra components or special components. Thus, the present invention eliminates the need for mechanical fasteners such as compression limiters or rivet nuts to thereby reduce complexity, reduce cost, reduce possibility of poor assembly, reduce assembly time, reduce weight.

The at least one overmold bracket <NUM> is selected from the group consisting of: at least one latch plate, at least one liftgate striker, at least one D-Pillar reinforcement, at least one shock plate, at least one strut plate, at least one hinge plate, at least one upper horizontal reinforcement, at least one side reinforcement, at least one vertical reinforcement, at least one corner liftgate reinforcement, at least one metal bracket, at least one steel bracket, at least one fiber reinforced molded bracket, and any combinations thereof.

The at least one predetermined liftgate attachment <NUM> is selected from the group consisting of: at least one hinge, ball stud, hat bracket, latch fasteners, weld nuts, bracket mounting, tether, and any combination thereof.

Referring more particularly to <FIG> generally, there is illustrated an exemplary liftgate assembly indicated generally at <NUM>, including an overmold <NUM> and at least one aperture <NUM> maintained for tether routing. There is provided at least one aperture (e.g., opening or hole) in at least one overmolded bracket <NUM>, e. g, reinforcement bracket, metal bracket, fiber reinforced bracket, etc. In accordance with the present invention, there is provided the creating of at least one aperture <NUM>, preferably, a plurality of holes, in at least one reinforcing bracket <NUM> for low cost tether routing of at least one tether <NUM> and maintaining the aperture <NUM> even with the bracket <NUM> over molding. At least one open mounting surface is provided. Preferably, a flange portion, indicated generally at <NUM>, has at least one overmolded bracket <NUM>. The over mold flange is provided and predetermined tool action produces the at least one aperture <NUM>. Optionally, a secondary operation produces at least one aperture <NUM>, if required. Optionally, at least one additional tether is provided or at least one opening created and maintained for at least one wire harnesses routing, substantially as set forth previously.

Referring to <FIG> generally, according to the present invention, there is created at least one aperture <NUM> in the stamping that is maintained in the molding operation, and, alternatively, through tool action such as a lifter, and/or at least one aperture is added post overmolding, as a secondary operation. The at least one aperture <NUM> (e.g., hold, opening, slit, etc) is maintained for tether <NUM> routing with the over molding process.

Putting apertures <NUM> in metallic reinforcements for tether routing creates a more efficient design. Overmolding metallic brackets creates an efficient method of combining the bracket <NUM> and molded liftgate panel; thus, overmolding the bracket and maintaining the aperture for tether routing creates an even more efficient and cost effective design.

The present invention maintains the overmolding of bracket advantage, and maintains an open aperture for tether routing. Thus, the present invention reduces complexity, costs, the chances of poor assembly and is more efficient and cost effective.

The liftgate <NUM> includes at least one panel <NUM>, preferably, at least one inner panel <NUM> and at least one outer panel <NUM>, most preferably at least one inner panel, at least one upper outer panel with show, Class-A surface, and at least one lower outer panel with show, Class-A surface. The liftgate is adapted to couple a rear window <NUM>, e.g., by adhesive <NUM>. The panel(s) <NUM> are predetermined materials suitable for strength and weight considerations, etc, e.g., composite, SMC, sheet metal composition, thermoplastic, etc. The reinforcements are preferably metal, e.g., steel, but any other suitable materials are contemplated, e.g., lighter weight metals, aluminum, plastics, carbon reinforced thermoplastics, etc. and any combinations thereof, depending on the application without departure from the present invention.

It is understood that while the present invention is adapted for a liftgate assembly as shown, the present invention is adaptable for any alternative assemby, e.g., door assembly, tailgate assembly, bumber, fender, roof top, rocker panel, etc, depending on the application without departure from the scope of the present invention. It is understood that the bracket is adaptable for attachment to any predetermined part, e.g., reinforcement, strut bracket, hinge bracket, plate bracket, pillar reinforcement, or any other part and combinations thereof, etc., depending on the application without departure from the scope of the present invention. While a metallic reinforcement is described it is understood that any alternatie suitable material is contemplated, e.g., metal, reinforced composite, etc., is contemplated depending on the application without departure from the scope of the present invention.

Claim 1:
A liftgate assembly (<NUM>) for a vehicle, comprising:
at least one liftgate panel including at least one reinforcement area;
at least one overmolded bracket (<NUM>) with at least one open mounting surface at at least one predetermined location adapted to selectively operably connect at least one predetermined liftgate attachments (<NUM>);
at least one aperture (<NUM>) maintained through the at least one overmolded bracket (<NUM>) adapted to selectively operably connect at least one further predetermined liftgate attachments (<NUM>); and characterized by comprising
at least one tether (<NUM>) routed through the at least one aperture (<NUM>).