Power tailgate mounting system for a vehicle

A single drawn sheet metal stamping is conventionally used to reinforce the location at which a power tailgate motor is mounted to the vehicle. While this works in many vehicle configurations, some vehicle package designs have an increased distance between the load point for the power tailgate motor and its attachment to the general body structure. Directional loading on the power tailgate motor under the forced closed loading condition can be severe and can require a very rigid mount for the motor. Use of the conventional reinforcement method could potentially result in deflection of the outer roof panel on the vehicle and is thus unacceptable.

According to one aspect, a power tailgate mounting system for a vehicle includes a first gusset member and a second gusset member. The first gusset member is secured to an inward side of a roof rail of the vehicle at a rear end portion of the roof rail. The first gusset member has a first gusset tailgate motor mounting portion extending laterally inwardly from the roof rail for mounting an associated tailgate motor. The second gusset member is secured to the inward side of the roof rail at the rear end portion of the roof rail. The second gusset member has a second gusset tailgate mounting portion extending laterally inwardly from the roof rail for mounting the associated tailgate motor. The second gusset tailgate mounting portion overlaps the first gusset tailgate mounting portion.

According to another aspect, a cantilevered motor mounting system for a vehicle tailgate motor includes a side roof rail, a first gusset member, and a second gusset member. The first gusset member is fixedly secured to the side roof rail adjacent and spaced forwardly relative to a terminal end of the side roof rail. The second gusset member is fixedly secured to the side roof rail adjacent and spaced forwardly relative to the terminal end of the side roof rail. The second gusset member is secured to the side roof rail at a second gusset location spaced apart rearwardly relative to a first gusset location at which the first gusset member is secured to the side roof rail. The first gusset member has a first gusset tailgate motor mounting portion extending laterally inwardly from the side roof rail and the second gusset member has a second gusset tailgate mounting portion extending laterally inwardly from the roof rail.

According to a further aspect, a vehicle mounting system includes a first gusset member and a second gusset member. The first gusset member is fixedly secured to an associated roof rail on a vehicle. The first gusset member has a first gusset tailgate motor mounting portion extending laterally inwardly from the roof rail for mounting an associated tailgate motor. The second gusset member is fixedly secured to the associated roof rail at a location spaced apart rearwardly from that at which the first gusset member is fixedly secured to the associated roof rail. The second gusset member has a second gusset tailgate mounting portion extending laterally inwardly from the roof rail for mounting the associated tailgate motor. The second gusset tailgate mounting portion overlaps the first gusset tailgate mounting portion.

FIG. 1 is a schematic partial perspective view of a power tailgate mounting system for a vehicle according to an exemplary embodiment shown from an inside perspective of the vehicle.

FIG. 2 is a view similar to FIG. 1 but shown with a motor cover disposed over the power tailgate motor and shown with a side airbag secured nearby.

FIG. 3 is a partial perspective view similar to FIG. 1 but shown enlarged and with the power tailgate motor removed to show a first gusset, a second gusset and an upper reinforcement member of the power tailgate mounting system.

FIG. 4 is a partial perspective view of the power tailgate mounting system of FIG. 1 but shown from an outside perspective of the vehicle to show an external reinforcement member of the power tailgate mounting system.

FIG. 5 is a schematic cross-sectional view taken along the line 5 - 5 of FIG. 2 .

FIG. 6 is an exploded perspective view of the power tailgate mounting system.

Referring now to the drawings wherein the showings are for purposes of illustrating one or more exemplary embodiments and not for purposes of limiting the same, FIGS. 1-6 show a power tailgate mounting system 10 for a vehicle 12 according to an exemplary embodiment. The mounting system 10 , which can also be referred to as a cantilevered motor mounting system, includes a first gusset member 14 and a second gusset member 16 . As shown, the first gusset member 14 is secured to an inward side 18 a of a roof rail 18 of the vehicle 12 at or adjacent a rear end portion 18 b of the roof rail 18 . The second gusset member 16 is likewise secured to the inward side 18 a of the roof rail 18 at or adjacent the rear end portion 18 b of the roof rail 18 . Herein, any securing of the components (e.g., the first and second gusset members 14 , 16 to the roof rail 18 ) can be via welding unless otherwise indicated.

The first gusset member 14 has a first gusset tailgate motor mounting portion 14 a extending laterally inwardly from the roof rail 18 for mounting an associated tailgate motor 20 . Likewise, the second gusset member 16 has a second gusset tailgate motor mounting portion 16 a extending laterally inwardly from the roof rail 18 for mounting the tailgate motor 20 . As will be described in more detail below, the second gusset tailgate motor mounting portion 16 a overlaps the first gusset tailgate motor mounting portion 14 a to provide a rigid mount for the tailgate motor 20 .

In the illustrated embodiment, the roof rail 18 is a side roof rail and the rear end portion 18 b of the roof rail 18 is a terminal end or end portion of the roof rail 18 . Thus, the first gusset member 14 is fixedly secured to the roof rail 18 adjacent and spaced forwardly relative to the terminal end 18 b of the roof rail 18 and the second gusset member 16 is fixedly secured to the roof rail 18 adjacent and spaced forwardly relative to the terminal end 18 b of the roof rail 18 . As shown, the second gusset member 16 is secured to the roof rail 18 at a second gusset location 22 spaced apart rearwardly relative to a first gusset location 24 at which the first gusset member 14 is secured to the roof rail 18 . Thus, the first gusset member 14 is fixedly secured to the roof rail 18 at the location 24 which is forwardly disposed (i.e., relative to a longitudinal direction of the vehicle 12 and of the roof rail 18 ) relative to the location 22 at which the second gusset member 16 is fixedly secured to the roof rail 18 .

More specifically, the first gusset member 14 includes a first gusset roof rail portion 14 b extending vertically along the inward side 18 a of the roof rail. Likewise, the second gusset member 16 includes a second gusset roof rail portion 16 b extending vertically along the inward side 18 a of the roof rail 18 . As shown, the first and second gusset roof rail portions 14 b , 16 b are spaced apart from one another along a longitudinal length of the roof rail 18 with the first gusset roof rail portion 14 b fixedly secured to the roof rail 18 at the first gusset location 24 and the second gusset roof rail portion fixedly secured to the roof rail 18 at the second gusset location 22 .

The first gusset tailgate motor mounting portion 14 a includes a first gusset distal mounting portion 14 c spaced apart laterally from the roof rail 18 and defining a first gusset aperture 14 d for mounting the tailgate motor 20 . Likewise, the second gusset tailgate motor mounting portion 16 a includes a second gusset distal mounting portion 16 c spaced apart laterally from the roof rail 18 and defining a second gusset aperture 16 d for mounting the tailgate motor 20 . The first and second gusset apertures 14 d , 16 d are in registry with one another for providing a mounting aperture 14 d , 16 d for the tailgate motor 20 . As best shown in FIG. 3 , the second gusset distal mounting portion 16 c overlaps the first gusset distal mounting portion 14 c . As shown, a plane of each of the first and second gusset apertures 14 d , 16 d is arranged generally parallel to the inward side 18 a of the roof rail 18 and spaced apart from the inward side 18 a of the roof rail 18 . The second gusset tailgate motor mounting portion includes a second gusset lower flange 16 e that overlaps and is secured to a first gusset lower flange 14 e of the first gusset tailgate motor mounting portion 14 a . As shown, the second gusset lower flange 16 e and the first gusset lower flange 14 e are oriented generally orthogonally relative to the inward side 18 a of the roof rail 18 .

The mounting system 10 can further include an outward reinforcement member 30 and an upper reinforcement member 32 . As best shown in FIG. 4 , the outward reinforcement member 30 , also referred to herein as an external reinforcement member, is secured to the roof rail 18 at a location or locations 34 , 36 opposite that at which the first and second gusset members 14 , 16 are fixedly secured to the roof rail 18 (i.e., at locations 22 and 24 ). More particularly, the outward reinforcement member 30 is secured to an outward side 18 c of the roof rail 18 at locations 34 , 36 directly opposite to where the first and second gusset members 14 , 16 are secured (i.e., at locations 22 and 24 ) to the inward side 18 a of the roof rail 18 . Specifically, the outward reinforcement member 30 includes a first flange portion 30 a overlapping the outward side 18 c of the roof rail 18 at the location or locations 34 directly opposite to where the first gusset member 14 is secured to the inward side 18 a of the roof rail 18 . Likewise, the reinforcement member 30 includes a second flange portion 30 b overlapping the outward side 18 c of the roof rail 18 at the location or locations 36 directly opposite to where the second gusset member 16 is secured to the inward side 18 a of the roof rail 18 .

Additionally, the outward reinforcement member 30 includes a first wall 30 c extending from the first flange portion 30 a and generally oriented orthogonally relative to the outward side 18 c of the roof rail 18 and the first flange portion 30 a , and a second wall 30 d extending from the second flange portion 30 b and generally oriented orthogonally relative to the outward side 18 c of the roof rail 18 and the second flange portion 30 b . Further, the outward reinforcement member 30 includes a connecting wall 30 e extending between the first wall 30 c and the second wall 30 d . The connecting wall 30 e is generally parallel to the outward side 18 c of the roof rail 18 and spaced apart from the outward side 18 c of the roof rail 18 .

The upper reinforcement member 32 overlaps and is secured to the first and second gusset tailgate motor mounting portions 14 a , 16 a of, respectively, the first and second gusset members 14 , 16 along upper flanges 14 f , 16 f thereof. More particularly, the upper reinforcement member 32 can be secured to each of the first and second gusset tailgate motor mounting portions 14 a , 16 a , and particularly to the respective upper flanges 14 f , 16 f of the first and second gusset tailgate motor mounting portions 14 a , 16 a that are spaced apart from one another along a longitudinal length of the roof rail 18 . More specifically, the first gusset tailgate motor mounting portion 14 a includes the first gusset upper flange 14 f to which the reinforcement member 32 overlaps and is secured (i.e., forming a first location at which the upper reinforcement member 32 is secured to the first and second gusset members 14 , 16 ). Likewise, the second gusset tailgate motor mounting portion 16 a includes the second gusset upper flange 16 f to which the reinforcement member 32 overlaps and is secured (i.e., forming a second location at which the upper reinforcement member 32 is secured to the first and second gusset members 14 , 16 ).

The first gusset upper flange 14 f defines a clip aperture 42 for mounting an associated wire harness clip 44 at a location 46 spaced inwardly relative to the roof rail 18 and forwardly relative to the terminal rearward end 18 b of the roof rail 18 . The wire harness clip carries a wire harness 48 as best shown in FIG. 2 . As illustrated, the first gusset lower flange 14 e is spaced apart vertically below the first gusset lower flange 14 e . Likewise, the second gusset lower flange 16 e is spaced apart vertically below the second gusset upper flange 16 f . As already discussed, the second gusset lower flange 16 e overlaps and is secured to the first gusset lower flange 14 e to provide a reinforced structure to which the vehicle tailgate motor 20 is mounted.

The roof rail 18 includes a roof rail upper flange 18 d extending angularly relative to the inward side 18 a (and the outward side 18 c ) of the roof rail 18 . The roof rail upper flange 18 d overlaps and is secured to an inward edge portion 32 a of the reinforcement member 32 . The reinforcement member 32 extends inwardly in a generally orthogonal orientation relative to the inward side 18 a of the roof rail 18 . The reinforcement member 32 also extends rearwardly from the first gusset member 14 and has a rearward portion 32 b secured to a corner structure 50 ( FIG. 3 ) at which the roof rail 18 terminates. As shown, the first and second gusset members 14 , 16 are spaced apart forwardly along the roof rail 18 relative to the corner structure 50 .

The mounting system 10 can additionally include features for accommodating an associated side airbag 52 (shown in FIG. 2 ). In particular, as shown best in FIGS. 1 and 3 , the roof rail 18 can include or define one or more (i.e., at least one) airbag mounting aperture 54 defined therein for mounting the side airbag 52 to the roof rail 18 . The one or more airbag apertures 54 are disposed between and spaced apart from both the first gusset roof rail portion 14 b and the second gusset roof rail portion 16 b . Accordingly, the first and second gusset members 14 , 16 , and particularly the first and second gusset roof rail portions 14 b , 16 b , provide the necessary rigidity for the mounting of the tailgate motor 20 while also enabling mounting access to the airbag apertures 54 defined in the roof rail 18 . Also, the connecting wall 30 e of the outward reinforcement member 30 can include an aperture or recess 30 f to expose the airbag apertures 54 defined in the roof rail 18 on the outward side 18 c of the roof rail 18 for mounting the side airbag 52 adjacent the inward side 18 a of the roof rail 18 . In particular, the mounting system 10 provides clearance for the side airbag 52 , including a side airbag bracket (not shown) and appropriate clearance for a tool (not shown) that is used to install a fastener to install the side airbag 52 to the roof rail 18 via the side airbag bracket.

The components of the mounting system 10 , which in the illustrated embodiment include the first gusset member, the second gusset member 16 , the outward reinforcement member 30 , and the upper reinforcement member 32 can be fixedly secured to one another and/or to the roof rail 18 via welding, as is known and understood by those skilled in the art. Additionally, a motor cover 56 (shown in FIGS. 2 and 5 ) can be fixedly connected, such as via welding, over the tailgate motor 20 and the mounting system 10 . As best shown in FIG. 5 , the first and second gusset members 14 , 16 , and particularly the distal mounting portions 14 c , 16 c having the apertures 14 d , 16 d defined therein provide a rigid mount for a ball stud 58 of the tailgate motor 20 . By the overlap between the first and second gusset members 14 , 16 , and also by the reinforcing provided by the reinforcement member 30 , 32 , the mounting system 10 provides a suitable rigid mount for the tailgate motor 20 .

It will be appreciated that various of the above-disclosed and other features and functions, or alternatives or varieties thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.