Patent ID: 12187351

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

DETAILED DESCRIPTION

FIG.1illustrates a vehicle10having a tailgate14according to one embodiment of the present disclosure. The vehicle10is depicted as a pickup truck having an open bed18(FIG.2) formed of opposing side walls22,26and the tailgate14. The tailgate14is configured to allow easy access to the space within the walls22,26of the bed18(FIG.2). While details of the present disclosure are given in the context of a light duty pickup truck, it will be understood that features described herein may also apply to the tailgates of other vehicles.

The tailgate14, as shown in inFIGS.1-4, is disposed at the rearmost end of the bed18laterally between the opposing side walls22,26. A lower portion16of the tailgate14is hingedly coupled to the vehicle10so that the tailgate14is rotatable relative to the vehicle10. In a closed position (FIG.1), a vertical height of the tailgate14, as measured from a lowermost point on the tailgate14to an uppermost point on the tailgate14, is substantially the same as a vertical height of the opposing side walls22,26, as measured from the base surface30of the bed18to the uppermost point on the sidewalls22,26. The tailgate14is substantially vertically oriented while in the closed position ofFIG.1. In other words, the tailgate14is oriented perpendicularly to the base surface30while in the closed position. The tailgate14of the illustrated embodiment, having the above described dimensions, is rectangular in shape.

FIGS.2-4illustrate the tailgate14in various open positions. To achieve the various open positions, the tailgate14includes multiple portions configured to be separately or jointly opened. Specifically, the tailgate14includes a major gate34and a minor gate38. The major gate34forms a primary portion of the tailgate14and is supported by the vehicle10, while the minor gate38forms a secondary portion of the tailgate14and is supported by the major gate34. The major gate34spans the lateral distance between the opposing side walls22,26of the vehicle10. The major gate34includes right and left lateral portions42,46which extend the vertical height of the tailgate14. A central portion44, between the lateral portions42,46, of the illustrated major gate34has a reduced overall height and represents about ⅔ of the vertical height of the tailgate14. In other words, the major gate34is “U” shaped. Located within an upper portion of the tailgate14is the minor gate38. The minor gate38is shaped to fit between the outer lateral portions42,46of the major gate34such that the combination of the major gate34and minor gate38forms the rectangular shape of the tailgate14. In other words, an overall rear view profile (e.g., rectangular profile) of the major gate34can be generally rectangular, with a cutout on a top side thereof. The cutout in the profile, which may occupy a majority but less than an entirety of a width of the rectangular profile, is filled by the minor gate38. In other embodiments, the relative sizes of the major and minor gates34,38may vary. For example, the minor gate38may span about ⅔ of the vertical distance of the tailgate14instead of the major gate34. The major and minor gates34,38may also equally divide the vertical length of the tailgate14. The respective upper edges of the minor gate38and the lateral outboard portions42,46of the major gate can be aligned with one another, when the minor gate38is closed, so that they cooperate to form a consistent upper edge of the tailgate14.

The major gate34is rotationally supported by the opposing side walls22,26, via a major hinge assembly62, while the minor gate38is rotationally supported by the major gate34via a minor hinge assembly74. The illustrated major hinge assembly62includes a left major hinge62L and a right major hinge62R, and the illustrated minor hinge assembly74includes a left minor hinge74L and a right minor hinge74R. The minor gate38does not directly engage the opposing side walls22,26or any other portion of the vehicle10. Only the major gate34directly engages the vehicle10. Specifically, the major gate34is configured to have 90 degrees of rotational freedom with respect to the base surface30, such that in a first open position, as shown inFIG.2, the major gate34(in particular, an interior wall thereof) is parallel to and coplanar with the base surface30of the bed18. The minor gate38is also configured to have 90 degrees of rotational freedom. However, rotation of the minor gate38is measured with respect to the major gate34, rather than the vehicle10. In an open position of the minor gate38only, as shown inFIG.3, the minor gate38(in particular, an interior wall thereof) is parallel to the base surface30of the bed18and perpendicular to the major gate34. From this position, opening the major gate34without closing the minor gate38results in the minor gate38being perpendicular to the base surface30of the bed, as shown inFIG.4. The major and minor gates34,38are configured to independently rotate to result in the various open positions ofFIGS.2-4. In the position ofFIG.2, the major gate34is open and the minor gate38is closed, resulting in an open configuration similar to a standard tailgate. In the position ofFIG.3, the major gate34is closed and the minor gate38is opened. Finally, in the position ofFIG.4, both the major gate34and the minor gate38are open.

The tailgate14includes a drive system48having drive units configured to separately open and close the major and minor gates34,38under power.FIG.5illustrates the drive system48of the tailgate14. Specifically, the drive system48includes a major gate drive unit50configured to rotate the major gate34and a minor gate drive unit54configured to rotate the minor gate38. Each drive unit50,54may include an electric motor, one or more gear sets, in particular planetary gear sets, one or more clutches, and one or more brakes. One or both of the drive units50,54can include an electromagnetic clutch that can be selectively opened and closed on command, although other clutches including passive slip clutches can also be used. Each drive unit50,54can be configured to provide one or both of powered opening and powered closing, including cinching closed for latching. One or both of the drive units50,54may include any or all of the features disclosed in U.S. Patent Application Publication No. 2020/0340282, the entirety of which is incorporated by reference herein. The major gate drive unit50is disposed within the major gate34and oriented such that an output end58faces laterally outward from a vertical centerline Cl of the tailgate14. Furthermore, the major gate drive unit50is located between the vertical centerline Cl and the right lateral portion42of the major gate34that the output end58faces. The major gate drive unit50is vertically located such that a rotational axis A1of the drive unit50is coaxial with a rotational axis A2of a major hinge assembly62, about which the major gate34rotates when opening and closing. The major hinge assembly62is located proximate the bottom most edge of the tailgate14. A major drive output member66, illustrated as a shaft, couples the major gate drive unit50to the major hinge assembly62for co-rotation. The major drive shaft66is sufficiently long so that the major gate drive unit50can be laterally located within the central portion44of the major gate34. In some embodiments, the major drive shaft66has a length L1of at least 20 mm, or at least 70 mm. Further, in some embodiments, the major drive shaft can be up to 650 mm in length. The central portion44, as previously defined, is the area between the right and left lateral portions42,46of the major gate34. Not counting the major drive shaft66, the entire major gate drive unit50can be positioned between the vertical centerline Cl and the right minor hinge74R.

With continued reference toFIG.5, the minor gate drive unit54is disposed within the major gate34and vertically located proximate a top edge of the central portion44of the major gate34. In other words, the minor gate drive unit54is disposed within the major gate34below the cutout. Similar to the major gate drive unit50, the minor gate drive unit54is laterally located within the central portion44of the major gate34and between the left minor hinge74L and the right minor hinge74R. More specifically, the minor gate drive unit54is located on the opposite side of the vertical centerline Cl than the major gate drive unit50and between the vertical centerline Cl and the left lateral portion46of the major gate34. A linkage assembly70, shown inFIG.6, operably couples the minor gate drive unit54to the left minor hinge assembly74L, which facilitates opening and closing of the minor gate38. Each of the left and right minor hinges74L,74R includes a first strap94, a second strap98, and a rotating assembly102. The first strap94is located within the minor gate38, and the second strap98is located within the major gate34and vertically aligned with the first strap94. The rotating assembly102connects the first and second straps94,98for rotation about a common axis A4, hereafter referred to the rotational axis of the minor hinge74. The linkage assembly70allows a rotational axis A3of the minor gate drive unit54to be vertically offset from the rotational axis A4of the minor hinge assembly74. Having a vertical offset between the axis A3and axis A4provides flexibility for the mounting location of the minor gate drive unit54. Specifically, the rotational axis A3is offset a distance D1from the rotational axis A4by at least 50 mm. For example, the offset distance D1may be at least 80 mm. In some embodiments, the offset distance D1is up to 100 mm, or up to 150 mm. Again, similar to the major gate drive unit50, the minor gate drive unit54is oriented such that an output end78faces laterally outward from the vertical centerline Cl. In other words, the output end78faces the left lateral portion46. The output ends58,78face opposite lateral portions42,46such that the major gate drive unit's output end58faces the right lateral portion42and the minor gate drive unit's output end78faces the left lateral portion46. In other embodiments, the output ends58,78may face the same lateral portion42,46of the major gate34, depending on the desired tailgate configuration and drive unit mounting locations. Not counting the linkage assembly70, the entire minor gate drive unit54can be positioned between the vertical centerline Cl and the adjacent minor hinge assembly74.

Details of the linkage assembly70for the minor gate drive unit54will now be given with respect toFIGS.6and7. A minor drive output member82, illustrated as a shaft, is rotationally coupled to the minor gate drive unit54at the output end78. The minor drive shaft82is parallel to and offset from the major drive shaft66. Furthermore, the minor drive shaft82is shorter in length than the major drive shaft66. The linkage assembly70further includes a drive link86and a drag link90which, together, couple the minor drive shaft82to the minor hinge74. The drive link86has a length (e.g., 50 mm) that is less than a length of the drag link90(e.g., 150 mm). The drive link86is coupled to the minor drive shaft82at one end and to the drag link90at the other end. The minor drive shaft82and drive link86are coupled in a rotationally fixed manner such that rotation of the minor drive shaft82results in an equivalent rotation of the drive link86. In other words, for one degree of rotation of the minor drive shaft82the drive link86rotates one degree. At the other end of the drive link86is a joint106at which the drag link90is coupled to the drive link86. The joint106as illustrated provided as a pivot that accommodates for relative rotation between the drive link86and the drag link90. The drag link90is further coupled to the first strap94of the minor hinge74for rotation therebetween at an actuating point110, for example an additional or “output” joint. The joint106between the drive link86and the drag link90and the actuating point110can each, respectively, be defined by a pivot pin that extends through a set of aligned apertures. The actuating point110is offset from the rotational axis A4of the minor hinge74. As will be understood by one of skill in the art, the offset between the minor hinge rotational axis A4and the actuating point110allows the linkage assembly70to rotate the first strap94about the minor hinge rotational axis A4, thus rotating the minor gate38about the rotational axis A4. To open the minor gate38, the minor gate drive unit54rotates the minor drive shaft82and subsequently the drive link86. Rotation of the drive link86forces the drag link90to move vertically upward, resulting in a vertically upward motion of the actuating point110. The vertical motion causes the first strap94to rotate about its rotational axis A4and open the minor gate38. To close the minor gate38, the minor gate drive unit54is rotated in a direction opposite the opening rotating direction, thus resulting in the drive link86forcing the drag link90to move vertically downward and closing the minor gate38.

With reference toFIG.5, the drive system48further includes a controller114operable to selectively actuate each of the major gate drive unit50and minor gate drive unit54. In particular, the controller114can be connected, as illustrated by the broken lines inFIG.5, to each of the major and minor gate drive units50,54by wires or a wireless communication protocol to convey signals from the controller114—and optionally back to the controller114. The controller114sends corresponding electrical control signals to the drive units50,54to actuate the respective drive units. Upon receipt of the respective control signals, the drive units50,54rotate the output ends58,78to open or close the major or minor gates34,38, respectively. For example, the controller114may send corresponding electric control signals in response to an operator's input to a button located on the vehicle10or on a fob associated with the vehicle10. The drive units50,54may be separately controlled by separate buttons or different inputs to the same button (e.g., push or push and hold). The controller114is configured to independently actuate each drive unit50,54, such that the drive units50,54may be actuated separately or at the same time. The resulting motion of the tailgate, depending on the signal(s) from the controller114, may be the major gate34opening (FIG.2), only the minor gate38opening (FIG.3), or both major and minor gates34,38opening (FIG.4). In the case of the major and minor gates34,38both opening, the gates34,38may rotate at the same time or one before the other. The major and minor gate drive units50,54can both be connected to receive power from the vehicle accessory power system, including a 12V battery (not shown).

Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the invention as described.

Various features of the invention are set forth in the following claims.