Modular vehicle liftgate module

• US 6,019,418 A
• Filed: 02/20/1998
• Issued: 02/01/2000
• Est. Priority Date: 07/31/1997
• Status: Expired due to Fees

• Current Assignee: International Automotive Components Group North America (Lear Corporation)
• Original Assignee: Lear Corporation
• Inventors: Thomas, David P. Jr., Emerling, David M., Morrison, Gerald O., Cannon, Carter S.
• Primary Examiner(s): Pape, Joseph D.
• Assistant Examiner(s): PATEL, KIRAN B
• Application Number:
  US09/027,079
• Time in Patent Office: 711 Days
• Field of Search: 296/56, 296/146.5-146.8, 296/106, 296/152, 296/76, 49/502
• US Class Current: 296/146.8
• CPC Class Codes: B60J 5/0416 Assembly panels to be installed in doors as a module with components, e.g. lock or window lifter, attached thereto
• CPC Class Codes: B60J 5/101 for non-load transporting vehicles, i.e. family cars including vans
• CPC Class Codes: B60J 5/107 constructional details, e.g. about door frame, panels, materials used, reinforcements

Abstract

An improved structural liftgate trim module for and a method of assembly a vehicle liftgate assembly of a liftgate for a motor vehicle having a modular structure consisting of an inner liftgate trim panel, an inner liftgate trim panel reinforcement member and an outer liftgate trim panel. The inner liftgate trim panel reinforcement member may include electrical components mounted to the reinforcement prior to assembly on the inner liftgate trim panel. The inner liftgate trim panel and inner liftgate trim panel reinforcement member are connected prior to assembly with an outer liftgate trim panel member by a mounting clip and at least one fastener. The inner liftgate trim panel reinforcement member includes flanged portions which are adapted to interface at accessible locations with flanged portions on the outer liftgate trim panel for easy-on, easy-off assembly. The structural liftgate trim module formed by the inner liftgate trim panel and inner liftgate trim panel reinforcement member is connected to the outer liftgate trim panel member by connecting at least one fastener from the structural liftgate trim module with a corresponding aperture on the outer liftgate trim panel and connecting each of the flanged portions on the module to the flanged portions on the outer liftgate trim panel to complete assembly of the vehicle liftgate.

Claims

1. A structural liftgate trim module for combining with and reinforcing a liftable outer liftgate panel of a motor vehicle to make a modular vehicle liftgate trim assembly, the structural liftgate trim module comprising:

an inner liftgate trim panel having an inner appearance side and an outer side having a structural characteristic, the inner appearance side being adapted to face into a passenger compartment of the motor vehicle and the outer side being adapted to face the outer liftgate panel; and

an inner liftgate trim panel reinforcement member having an inner side adapted to mount to the outer side of the inner liftgate trim panel to provide the structural characteristic and an outer side adapted to interface with the outer liftgate panel, the inner liftgate trim panel reinforcement member being sufficiently light to be liftable in the liftgate assembly and having spaced portions adapted to interface with the outer liftgate panel in respective spaced locations with each spaced portion being readily accessible and operable to detachably and structurally secure the inner liftgate trim panel in an easy-on, easy-off combination with the outer liftgate panel.

2. The structural liftgate trim module of claim 1 wherein the spaced locations are on opposite sides of the inner liftgate trim panel so that the spaced portions of the inner liftgate trim reinforcement are more readily accessible when securing the inner liftgate trim panel in combination with the outer liftgate panel.

3. The structural liftgate trim module of claim 1 including a lock and catch assembly for selectively locking and unlocking the outer liftgate panel with respect to the motor vehicle when the inner liftgate trim panel and inner liftgate trim panel reinforcement member are secured in combination with the outer liftgate panel, the lock and catch assembly being sufficiently adjacent to one of the spaced portions of the inner liftgate trim panel reinforcement member that the lock is readily accessible and operable to detachably and structurally secure the lock and catch assembly in combination with the outer liftgate panel in one of the spaced locations when the inner liftgate trim panel is secured in combination with the outer liftgate panel.

4. The structural liftgate trim module of claim 3 wherein one of the spaced portions of the inner liftgate trim panel reinforcement member is configured substantially normal to the inner liftgate trim panel adjacent the lock and catch assembly to cause the one of the spaced portions in one of the spaced locations to interface with a peripheral portion of the outer liftgate panel when both the inner liftgate trim panel and the lock and catch assembly are secured in combination with the outer liftgate panel.

5. The structural liftgate trim module of claim 3 wherein the lock and catch assembly is mounted on the inner liftgate trim panel reinforcement member, the lock and catch assembly comprising a latch mounting bracket and a lock assembly mounted within the latch mounting bracket.

6. The structural liftgate trim module of claim 1 wherein the lock and catch assembly further comprises a handle for operating the lock and catch assembly, the handle adapted to extend into an exterior hand grab position through the outer liftgate panel when the inner liftgate trim panel and inner liftgate trim panel reinforcement member are secured in combination with the outer liftgate panel.

7. The structural liftgate trim module of claim 1 wherein the inner liftgate trim panel reinforcement member further comprises at least one connecting portion provided on the inner side of the inner liftgate trim panel reinforcement member.

8. The structural liftgate trim module of claim 1 further comprising a retaining member removably mounted to the at least one connecting portion of the inner liftgate trim panel reinforcement member, the retaining member engaging a portion of the outer side of the inner liftgate trim panel to hold the inner liftgate trim panel reinforcement member and the inner liftgate trim panel in a locking engagement prior to assembly of the structural liftgate trim module.

9. The structural liftgate trim module of claim 1 wherein the inner liftgate trim panel further comprises at least one seat provided on the outer side of the inner liftgate trim panel, the at least one seat being adapted to receive at least one fastener.

10. The structural liftgate trim module of claim 1 wherein the inner liftgate trim panel reinforcement member further comprises at least one aperture extending through the inner liftgate trim panel reinforcement member in a corresponding relationship to the at least one seat on the outer side of the inner liftgate trim panel.

11. The structural liftgate trim module of claim 1 wherein the outer liftgate panel further comprises at least one aperture in a corresponding relationship with the at least one seat on the outer side of the inner liftgate trim panel and the at least one aperture on the inner liftgate trim panel reinforcement member, the at least one aperture of the outer liftgate panel adapted to receive a fastener mounted in the at least one seat.

12. The structural liftgate trim module of claim 1 wherein the outer liftgate panel has at least one aperture and wherein the inner liftgate trim panel reinforcement member further comprises at least one fastener member integrally formed an the outer side of the reinforcement member corresponding to the at least one aperture of the outer liftgate panel to lockingly engage the structural liftgate trim module and the outer liftgate panel.

13. The structural liftgate trim module of claim 1 wherein the inner liftgate trim panel reinforcement member is configured to resist crash loads impacting the motor vehicle.

14. The structural liftgate trim module of claim 1 wherein the inner liftgate trim panel reinforcement member comprises metal.

15. The structural liftgate trim module of claim 1 wherein the inner liftgate trim panel reinforcement member comprises plastic.

16. The structural liftgate trim module of claim 1 wherein the inner liftgate trim panel is injection molded.

17. The structural liftgate trim module of claim 1 wherein the inner liftgate trim panel is compression molded.

18. The structural liftgate trim module of claim 1 wherein the inner liftgate trim panel comprises polyolefin thermoplastic.

19. The structural liftgate trim module of claim 1 wherein the inner liftgate trim panel comprises polypropylene.

20. The structural liftgate trim module of claim 1 wherein the inner liftgate trim panel comprises acrylonitrile-butadiene-styrene.

21. The structural liftgate trim module of claim 1 wherein the inner liftgate trim panel comprises a glass-reinforced composite.

22. The structural liftgate trim module of claim 1 wherein a wiper bracket assembly is mounted to the inner liftgate trim panel reinforcement member.

23. The structural liftgate trim module of claim 22 wherein the wiper bracket assembly is spot welded to the inner liftgate trim panel reinforcement member.

24. The structural liftgate trim module of claim 22 wherein a wiper motor is attached to the wiper bracket assembly.

25. The structural liftgate trim module of claim 1 wherein at least one electrical component is mounted on the inner liftgate trim panel reinforcement member of the structural liftgate trim module.

26. The structural liftgate trim module of claim 25 wherein at least one electrical component includes an electric actuating mechanism mounted to the inner liftgate trim panel reinforcement member.

27. The structural liftgate trim module of claim 26 wherein the electric actuating mechanism is adapted to be coupled with a lock and catch assembly to open and close the liftgate trim.

28. The structural liftgate trim module of claim 25 wherein the at least one electrical component is a brake light assembly mounted to the inner liftgate trim panel reinforcement member.

29. The structural liftgate trim module of claim 1 further comprising a wiring harness connected to the outer side of the inner liftgate trim panel.

30. The structural liftgate trim module of claim 29 including a wiper motor component mounted on the inner liftgate trim panel reinforcement member and wherein the wiring harness is connected to the wiper motor.

31. The structural liftgate trim module of claim 29 including an electric actuating mechanism mounted on the inner liftgate trim panel reinforcement member and wherein the wiring harness is connected to the electric actuating mechanism.

32. The structural liftgate trim module of claim 29 including a brake light assembly mounted on the inner liftgate trim panel reinforcement member and wherein the wiring harness is connected to the brake light assembly.

33. The structural liftgate trim module of claim 25 including a water management panel mounted between the inner and outer liftgate trim panels.

34. The structural liftgate trim module of claim 33 wherein the water management panel includes a flange on the inner liftgate trim panel reinforcement member and a belt line glass seal attached to the flange as part of the water management system.

35. The structural liftgate trim module of claim 33 wherein the water management panel is a sheet configured to conformingly seal the at least one electrical component mounted to the inner liftgate trim panel reinforcement member.

36. A modular vehicle liftgate assembly for a motor vehicle comprising an outer liftgate panel having a peripheral flange defining an opening, and a structural liftgate trim module insertable into said opening and having a plurality of electrical components testable and adjustable before said structural liftgate trim module is inserted into said opening, said structural liftgate trim module including:

an inner liftgate trim panel having an inner appearance side and an outer side having a structural characteristic for the vehicle liftgate trim assembly, the inner appearance side being adapted to face into a passenger compartment of the motor vehicle and the outer side facing the outer liftgate panel; and

an inner liftgate trim panel reinforcement member having an inner side adapted to mount on the outer side of the inner liftgate trim panel to provide the structural characteristic and outer side adapted to interface with the outer liftgate panel, the inner liftgate trim panel reinforcement member having spaced portions at least one of which interfaces with the peripheral flange of the outer liftgate panel and with the peripheral flange of the outer liftgate panel and with each spaced portion being readily accessible and operable to detachably and structurally secure the inner liftgate trim panel in an easy-on, easy-off combination with the outer liftgate panel.

37. The vehicle liftgate trim assembly of claim 36 wherein the peripheral flange extends between the inner liftgate trim panel and the outer liftgate panel.

38. A method of assembling a modular liftgate assembly for a motor vehicle comprising:

providing an outer liftgate panel with a peripheral flange having a first flange portion substantially normal to the outer liftgate panel and a second flange portion spaced from the first portion and substantially parallel to the outer liftgate panel;

forming a structural liftgate trim module comprising an inner liftgate trim panel having an inner appearance side and an outer side having a structural characteristic, the inner appearance side being adapted to face into a passenger compartment of the motor vehicle and the outer side being adapted to face the outer liftgate panel;

mounting an inner liftgate trim panel reinforcement member on the outer side of the inner liftgate trim panel to provide the structural characteristic of the inner liftgate trim panel, and forming at least one spaced reinforcement flange portions on the inner liftgate trim panel reinforcement member adapted to interface respectively with the first and second flange portions on the outer liftgate panel;

positioning the structural liftgate trim module adjacent the outer liftgate panel so that one of the at least one reinforcement flange portions is readily accessible and interfaces with the first outer liftgate panel flange portion and another of the at least one reinforcement flange portions is readily accessible and interfaces with the second outer liftgate panel flange portion; and

detachably securing the structural liftgate trim module to the outer liftgate panel by fastening each of the at least one reinforcement flange portions to a respective outer liftgate panel flange portion whereby to reinforce the outer liftgate panel with the structural liftgate trim module.

39. The method of assembling the modular liftgate assembly of claim 38 including:

installing as a part of the structural liftgate trim module at least one electrical component on the outer side of the inner liftgate trim panel reinforcement member and sealing the outer side and the electrical component with a watershield before the structural liftgate trim module is positioned adjacent the outer liftgate panel whereby to shield the electrical component and the passenger compartment of the vehicle from the deleterious effects of water, noise and dust.