U.S. patent application number 15/884728 was filed with the patent office on 2019-08-01 for two-piece deck post.
The applicant listed for this patent is Toyota Motor Engineering & Manufacturing North America, Inc.. Invention is credited to Scott L. Frederick, Christopher M. Higgins, Yasuyuki Hihara, Adam D. Holmstrom, Scott P. Robison.
Application Number | 20190233021 15/884728 |
Document ID | / |
Family ID | 67106443 |
Filed Date | 2019-08-01 |
United States Patent
Application |
20190233021 |
Kind Code |
A1 |
Hihara; Yasuyuki ; et
al. |
August 1, 2019 |
TWO-PIECE DECK POST
Abstract
A rear deck post assembly is provided for reinforcing a cargo
bed of a utility vehicle. The assembly includes a first deck mount
coupled to a vehicle frame, and a first rear deck post coupled to
the first deck mount. A second deck mount is provided coupled to
the vehicle frame and spaced apart from the first deck mount. A
second rear deck post is coupled to the second deck mount. A deck
sill component is provided longitudinally extending between the
first deck post and the second deck post. Deck bolts may be used to
couple the deck sill component, deck mounts, and deck posts to the
vehicle frame. The first and second deck mounts and deck posts may
be a cast aluminum alloy, a cast magnesium alloy, or a fiber
reinforced composite material.
Inventors: |
Hihara; Yasuyuki; (Canton,
MI) ; Higgins; Christopher M.; (Ann Arbor, MI)
; Robison; Scott P.; (Dexter, MI) ; Frederick;
Scott L.; (Brighton, MI) ; Holmstrom; Adam D.;
(Pinckney, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Toyota Motor Engineering & Manufacturing North America,
Inc. |
Erlanger |
KY |
US |
|
|
Family ID: |
67106443 |
Appl. No.: |
15/884728 |
Filed: |
January 31, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B62D 29/008 20130101;
B62D 33/02 20130101; B62D 33/023 20130101; B62D 33/0273 20130101;
B62D 29/001 20130101 |
International
Class: |
B62D 29/00 20060101
B62D029/00; B62D 33/023 20060101 B62D033/023 |
Claims
1. A rear deck post assembly for reinforcing a cargo bed of a
utility vehicle, the assembly comprising: a first deck mount
coupled to a vehicle frame; a first rear deck post coupled to the
first deck mount; a second deck mount coupled to the vehicle frame
and spaced apart from the first deck mount; a second rear deck post
coupled to the second deck mount; a deck sill component
longitudinally extending between the first rear deck post and the
second rear deck post, the deck sill component being formed using
extrusion techniques and defining a U-shaped sleeve having a
substantially uniform cross-section along a length dimension,
wherein at least a portion of the first rear deck post and the
second rear deck post define an exterior surface of the cargo bed
of the utility vehicle that is exposed to an external
environment.
2. The rear deck post assembly according to claim 1, wherein the
first rear deck post and the second rear deck post comprise a cast
aluminum alloy.
3. The rear deck post assembly according to claim 1, wherein the
first rear deck post and the second rear deck post comprise a cast
magnesium alloy.
4. The rear deck post assembly according to claim 1, wherein the
first rear deck post and the second rear deck post comprise a fiber
reinforced composite material.
5. (canceled)
6. A rear deck post assembly for reinforcing a cargo bed of a
utility vehicle, the assembly comprising: a first deck mount
coupled to a vehicle frame; a first rear deck post coupled to the
first deck mount; a second deck mount coupled to the vehicle frame
and spaced apart from the first deck mount; a second rear deck post
coupled to the second deck mount; a deck sill component
longitudinally extending between the first rear deck post and the
second rear deck post, wherein respective walls of the first rear
deck post and the second rear deck post define an interior cavity
comprising a plurality of lateral ribs and X-shaped ribs extending
between opposing walls.
7. A rear deck post assembly for reinforcing a cargo bed of a
utility vehicle, the assembly comprising: a first deck mount
coupled to a vehicle frame; a first rear deck post coupled to the
first deck mount; a second deck mount coupled to the vehicle frame
and spaced apart from the first deck mount; a second rear deck post
coupled to the second deck mount; a deck sill component
longitudinally extending between the first rear deck post and the
second rear deck post, wherein the first rear deck post and the
second rear deck post comprise a vertically extending pillar
portion and a horizontally extending coupling portion, wherein
respective walls of the pillar portion define a plurality of
regions, each region having a different wall thickness.
8. The rear deck post assembly according to claim 7, wherein the
plurality of regions includes an upper region defining an upper
wall thickness and a lower region defining a lower wall thickness
that is greater than the upper wall thickness.
9. The rear deck post assembly according to claim 8, wherein the
wall thickness is provided with a thickness gradient that increases
in a direction from the upper region to the lower region.
10. The rear deck post assembly according to claim 8, wherein the
lower region is wider than the upper region.
11. The rear deck post assembly according to claim 7, wherein the
first rear deck post and the second rear deck post are configured
to exhibit a tapering I-value that is greatest at the lower region
in order to minimize any deflection from a force applied to the
respective rear deck post.
12. The rear deck post assembly according to claim 11, wherein the
deck sill component is configured to exhibit a substantially
constant I-value along a length dimension in order to evenly
distribute the applied force in a longitudinal direction across a
length of the deck sill component.
13. The rear deck post assembly according to claim 1, wherein the
deck sill component is coupled to the first and second deck mounts
and the vehicle frame.
14. The rear deck post assembly according to claim 1, wherein the
deck sill component is disposed underneath a bed floor of the cargo
bed.
15. The rear deck post assembly according to claim 1, wherein each
deck mount comprises a cast aluminum main body portion, a
horizontally extending flange portion, and a vertically extending
flange portion.
16. A reinforced cargo area for a pickup truck, the reinforced
cargo area comprising: a frame; a cargo bed coupled to the frame
and having a forward end, a rearward end, two opposing sidewalls,
and a bed floor; a first cast alloy deck mount coupled to the frame
at the rearward end of the cargo bed; a first cast alloy rear deck
post coupled to the first cast alloy deck mount; a second cast
alloy deck mount coupled to the frame at the rearward end of the
cargo bed and spaced apart from the first cast alloy deck mount; a
second cast alloy rear deck post coupled to the second cast alloy
deck mount; and a deck sill component disposed underneath the bed
floor and longitudinally extending between the first cast alloy
rear deck post and the second cast alloy rear deck post, wherein
the first and second cast alloy rear deck posts comprise a
vertically extending pillar portion and a horizontally extending
coupling portion, further wherein respective walls of the pillar
portion define a plurality of regions, each region having a
different wall thickness.
17. The reinforced cargo area according to claim 16, wherein the
first and second cast alloy deck mounts and cast alloy deck posts
comprise at least one of an aluminum alloy and a magnesium
alloy.
18. (canceled)
19. The reinforced cargo area according to claim 16, wherein the
pillar portion is configured to exhibit a tapering I-value that is
greatest at a lower region near the horizontally extending coupling
portion in order to minimize any deflection from a force applied to
deck post.
20. A pickup truck with a reinforced cargo area, comprising: a
frame; a cargo bed coupled to the frame and having a forward end, a
rearward end, two opposing sidewalls, and a bed floor; first and
second spaced apart two-piece deck post assemblies, each two-piece
deck post assembly comprising a cast aluminum deck mount coupled to
the frame at the rearward end of the cargo bed, and a cast aluminum
deck post coupled to the respective deck mount, each deck post
comprising a vertically extending pillar portion and a horizontally
extending coupling portion; and a deck sill component formed using
extrusion techniques and defining a U-shaped sleeve having a
substantially uniform cross-section along a length dimension, the
deck sill component coupled to the deck mounts and longitudinally
extending between the horizontally extending coupling portions of
the deck posts, wherein the pillar portion of each deck post is
configured to exhibit a tapering I-value that is greatest at a
lower region near the horizontally extending coupling portion in
order to minimize any deflection from a force applied to the
respective rear deck post assembly.
Description
TECHNICAL FIELD
[0001] The present disclosure generally relates to deck posts, and
more particularly, to a two-piece deck post assembly for a pickup
truck utility vehicle.
BACKGROUND
[0002] The background description provided herein is for the
purpose of generally presenting the context of the disclosure. Work
of the presently named inventors, to the extent it may be described
in this background section, as well as aspects of the description
that may not otherwise qualify as prior art at the time of filing,
are neither expressly nor impliedly admitted as prior art against
the present technology.
[0003] Utility vehicle cargo beds such as truck beds, and the like,
should be robust in order to withstand wear and tear from normal
use. In one specific example, truck beds of pickup trucks may be
provided with front and rear deck posts as major structural
components. The deck posts are commonly made of numerous components
and parts that are mechanically fastened or welded together. For
example, it is not unusual for a deck post to be made of nine or
more separate pieces in order to withstand the potential inboard,
outboard, and the resulting cantilevered forces that may arise
under different deck loading conditions. Preferably the deck posts
are also designed to accommodate forces and loads from auxiliary
components, such as tie down hooks. In addition to the strength
considerations, the deck posts are also a common place to
accommodate tail lights, tailgate hinges, tailgate stoppers,
tailgate dampeners, stake pockets, and more. Thus, the rear deck
posts may need to be provided with apertures and other connection
mechanisms. Such strength and design considerations have led to
complex assemblies that may require additional tools or assembly
steps, may lead to additional component weight, and ultimately
result in higher costs of manufacture.
[0004] Accordingly, it would be desirable to provide an improved
deck post design that maintains the strength requirements while
lowering and/or minimizing weight and costs of manufacture and
production.
SUMMARY
[0005] This section provides a general summary of the disclosure,
and is not a comprehensive disclosure of its full scope or all of
its features.
[0006] In various aspects, the present teachings provide a
two-piece rear deck post assembly for reinforcing a cargo bed of a
utility vehicle. The assembly includes a first deck mount coupled
to a vehicle frame, and a first rear deck post coupled to the first
deck mount. A second deck mount is provided coupled to the vehicle
frame and spaced apart from the first deck mount. A second rear
deck post is coupled to the second deck post. A deck sill component
is provided longitudinally extending between the first deck post
and the second deck post. In various aspects, at least a portion of
each of the first rear deck post and the second rear deck post
defines an exterior surface of the cargo bed of the utility vehicle
that is exposed to an external environment. The first and second
deck mounts and deck posts may be a cast aluminum alloy, a cast
magnesium alloy, or a fiber reinforced composite material.
[0007] In other aspects, the present teachings provide a reinforced
cargo area for a pickup truck. The reinforced cargo bed includes a
frame and a cargo bed coupled to the frame. The cargo bed may
include a forward end, a rearward end, two opposing sidewalls, and
a bed floor. A first cast alloy deck mount is provided, coupled to
the frame at the rearward end of the cargo bed. A first cast alloy
rear deck post is coupled to the first cast alloy deck mount. A
second cast alloy deck mount is coupled to the frame at the
rearward end of the cargo bed and spaced apart from the first cast
alloy deck mount. A second cast alloy rear deck post is coupled to
the second cast alloy deck mount. A deck sill component is
provided, longitudinally extending between the first cast alloy
rear deck post and the second cast alloy deck post. In various
aspects, at least a portion of the first rear deck post and the
second rear deck post define an exterior surface of the cargo bed
that is exposed to an external environment. The deck sill component
may be disposed underneath the bed floor.
[0008] In still other aspects, the present teachings provide a
pickup truck with a reinforced cargo area. The pickup truck
includes a frame and a cargo bed coupled to the frame and having a
forward end, a rearward end, two opposing sidewalls, and a bed
floor. First and second spaced apart two-piece deck post assemblies
are provided. Each deck post assembly includes a cast aluminum deck
mount coupled to the frame at the rearward end of the cargo bed,
and a cast aluminum deck post coupled to the respective deck mount.
Each deck post includes a vertically extending pillar portion and a
horizontally extending coupling portion. A deck sill component is
provided, formed using extrusion techniques and defining a U-shaped
sleeve having a substantially uniform cross-section along a length
dimension. The deck sill component is coupled to the deck mounts
and longitudinally extends between the horizontally extending
coupling portions of the deck posts. In various aspects, the pillar
portion of each deck post is configured to exhibit a tapering
I-value that is greatest at a lower region near the horizontally
extending coupling portion in order to minimize any deflection from
a force applied to the respective rear deck post assembly.
[0009] Further areas of applicability and various methods of
enhancing the above technology will become apparent from the
description provided herein. The description and specific examples
in this summary are intended for purposes of illustration only and
are not intended to limit the scope of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The present teachings will become more fully understood from
the detailed description and the accompanying drawings,
wherein:
[0011] FIG. 1 is a rear perspective view of an exemplary pickup
truck type of utility vehicle having a cargo bed that can benefit
from the two-piece deck post assembly of the present
technology;
[0012] FIG. 2 is a rear plan view of a combination of left and
right side two-piece rear deck post assemblies with a deck sill
component extending there between for reinforcing a cargo bed of a
utility vehicle according to various aspects of the present
technology;
[0013] FIGS. 3A and 3B are partial top plan views of the two rear
deck post assemblies as provided of FIG. 2;
[0014] FIG. 4 is a partial exploded view of the combination of FIG.
2 illustrating the separate components;
[0015] FIG. 5 is a cross-sectional view of the deck sill component
of FIG. 4 taken along the line 5-5;
[0016] FIG. 6 is a side perspective view of an exemplary two-piece
deck post according to various aspects of the present
technology;
[0017] FIG. 7 is a side plan view of an exemplary rear deck post
illustrating details of a cavity defined in the pillar and having a
plurality of internal web, or rib, features;
[0018] FIG. 8 is a first side perspective view of an exemplary deck
mount;
[0019] FIG. 9 is a second side perspective view of the exemplary
deck mount, rotated about 180 degrees from the view as shown in
FIG. 8; and
[0020] FIG. 10 is a bottom perspective view of the exemplary deck
mount illustrating various internal web, or rib features.
[0021] It should be noted that the figures set forth herein are
intended to exemplify the general characteristics of the devices,
methods, and algorithms among those of the present technology, for
the purpose of the description of certain aspects. These figures
may not precisely reflect the characteristics of any given aspect,
and are not necessarily intended to define or limit specific
embodiments within the scope of this technology. Further, certain
aspects may incorporate features from a combination of the
figures.
DETAILED DESCRIPTION
[0022] The present technology generally provides a more simplified
two-piece rear deck post assembly for a utility type vehicle that
includes a cargo area for transporting items, such as a cargo bed
or truck bed of a pickup truck, or the like. Generally, the present
technology provides first and second spaced apart two-piece rear
deck post assemblies. Each two-piece rear deck post assembly
includes a deck mount that is coupled to at least one frame
component of the utility vehicle, for example at the rearward end
of the cargo bed. Each two-piece deck post assembly also includes a
deck post coupled to the respective deck mount. As will be
described in more detail below, the deck post may include a
vertically extending pillar portion and a horizontally extending
coupling portion. The deck mounts and the deck posts may be a cast
metal, such as an aluminum alloy or a magnesium alloy. Forming the
components as a cast metal allows for the incorporation of various
useful features that can be specifically designed and tailored in
the mold or cast. A deck sill component is also provided,
preferably formed using extrusion techniques and defining a
U-shaped sleeve having a substantially uniform cross-section along
a length dimension. The deck sill component is coupled to the deck
mounts and longitudinally extends between the horizontally
extending coupling portions of the deck posts.
[0023] FIG. 1 is a rear perspective view of an exemplary pickup
truck type of utility vehicle having a cargo bed that can benefit
from the two-piece deck post assembly of the present technology. As
illustrated, the pickup truck 20 may include a passenger
compartment 22 and a front end 24. A rear portion of the pickup
truck 20 can include a cargo area, or cargo bed 26, that is coupled
to the vehicle frame at various locations and is configured for
transporting cargo, as well as for various other uses. The cargo
bed 26 may generally be provided with a forward end 28, a rearward
end 30, two opposing sidewalls 32, 34, and a bed floor 36. A
tailgate 38 may be provided pivotally coupled to a rearward end 30
of the cargo bed 26, preferably secured to the deck posts.
[0024] While the present technology may be described and presented
in the drawings with respect to a pickup truck as an exemplary
utility vehicle, it should be understood that the two-piece post
assemblies disclosed herein may be used with a variety of
differently configured vehicles with cargo areas or cargo beds, for
travel either on paved government streets/roads as well as for
off-road use.
[0025] FIG. 2 is a rear plan view of a combination 40 of left and
right side two-piece rear deck post assemblies 42, 44 with a deck
sill component 46 extending there between for reinforcing the cargo
bed 26 of a utility vehicle 20 according to various aspects of the
present technology. Each two-piece rear deck post assembly 42, 44
includes a deck mount 48 that is configured to be coupled to at
least one vehicle frame component (see, FIG. 6) and a deck post 50.
As will be described in more detail below, the deck post 50 may
generally include a vertically extending pillar portion 52 and a
horizontally extending coupling portion 54. The intersection of the
pillar 52 and coupling portion 54 may be provided with a curved or
rounded exterior surface 56.
[0026] With renewed reference to FIG. 1, it should be understood
that the distal or rearward end 30 of the cargo bed 26 should be
designed to perform under unique loading requirements due to the
different types of forces and loads that may be applied from cargo
or auxiliary components. In various aspects, auxiliary components,
such as tie down hooks, may exert forces against the cargo bed,
originating from multiple angles and direction. The opposing
sidewalls 32, 34 of the cargo box may experience forces and loads
applied in various direction from the use of other auxiliary items
such as tool boxes, ladders, cargo, and the like. Preferably all,
or at least a portion, of these forces and applied loads are
ultimately transferred to a frame component of the vehicle. With
the present technology, preferably the forces and applied loads are
transferred to the vehicle frame via the rear deck posts 50,
respective deck mounts 48, and the deck sill component 46.
[0027] F.sub.1 and F.sub.2 of FIG. 1 depict outwardly and inwardly
applied forces, respectively. For illustrative purposes, box 58
generally represents the structural support provided by the deck
post assembly 44, and box 60 represents the structural support
provided by the deck sill component 46. If F.sub.1 represents an
exemplary 150 kg force applied to an upper region of the rear deck
post assembly 44 area, the rear deck post 50 needs to be configured
to absorb a load at the top portion of the post. In turn, the
bottom portion of the rear deck post 50 will exert a moment on the
distal end of the deck sill component 46. Thus, the rearward end of
the sidewalls should be configured to withstand, among other
forces, cantilevered forces. Accordingly, it is desirable to have a
deck sill component 46 and a rear post assembly 44 that is
optimized to withstand the cantilevered forces applied to the rear
deck post 50.
[0028] In various aspects, the deck mount 48 and deck post 50
components made according to the present technology are a die cast
metal alloy or a high strength fiber reinforced composite material.
Metal casting processes generally force molten metal under high
pressure into a mold cavity. Slide die casting processes may be
useful with the present technology, and use a number of
perpendicular slides in the mold tool enabling very complex and
accurate castings to be produced.
[0029] Aluminum and aluminum alloy castings have very good strength
and hardness, and components can be die cast with relatively thin
walls such they are lightweight and can contribute to weight
savings and fuel efficiency. Further, they can be die cast with
complex, intricate, and purposeful shapes and designs, with
different thicknesses in different portions and regions in order to
tailor the strength and other properties. Aluminum alloy castings
are generally able to withstand the highest of operating
temperatures of most die cast alloys while also providing
outstanding corrosion resistance and heat dissipating properties.
One exemplary aluminum alloy useful with the present technology is
UNS A03650. Similarly, magnesium is an extremely versatile material
and one of the lightest structural materials, about 33% lighter
than aluminum. Magnesium alloys may provide increased stiffness and
the strength-to-weight ratio of magnesium alloys is generally
comparable with that of the strong alloys of aluminum. Alloy AZ91D
is one of the most widely used magnesium die cast alloy and has an
excellent combination of mechanical properties, corrosion
resistance, and castability. Thus, in certain examples, the deck
mount 48 and deck post 50 components can be made of a cast aluminum
alloy, a cast magnesium alloy, a fiber reinforced composite, or a
combination thereof.
[0030] The deck sill component 46 is preferably an aluminum or
magnesium metal extrusion, such that it can be formed having a
substantially uniform cross section along its length dimension as
best shown in FIGS. 4 and 5. In other aspects, the deck sill
component can be a stamped or otherwise formed or shaped metal or
high strength composite material, i.e., not extruded, but similarly
having a substantially constant cross-section for most of the
length dimension. One of the advantages of having the uniform or
substantially constant cross section is that it provides the
ability for a constant transfer of load or applied force across the
length dimension.
[0031] Other components of the vehicle 20, such as the tailgate 38
and the sidewall panels 32 and 34, may be made of five thousand
series or six thousand series wrought aluminum alloy. For example,
various wrought aluminum alloys are generally identified by a four
digit number. The first digit generally identifies the major
alloying element, and may be followed by three x's or three 0's
(zeros). For example, the major alloying element of 5xxx or 5000
series aluminum alloy is magnesium, the major alloying element in
6xxx or 6000 series is magnesium and silicon, and the major
alloying element of 7xxx or 7000 series is zinc. Additional numbers
represented by the letter `x` or number `0` in the series
designation define the exact aluminum alloy. As should be
understood, the various different metal alloys may provide any
number of different tradeoffs pertaining to the strength, hardness,
and workability of the metal alloy, as well as other properties
that may be of consideration.
[0032] FIGS. 3A and 3B are partial top plan views of the two rear
deck post assemblies 42, 44 as provided of FIG. 2 showing
additional details. For a better understanding of the mechanical
connections between the components, FIG. 4 is a partial exploded
view of the combination of FIG. 2 illustrating the separate
components including the deck sill component 46, one of the deck
mounts 48, and a rear deck post 50. In the specific design shown,
one standard assembly would be for the deck post 50 to be coupled
to the deck mount 48 to form each two-piece assembly 42, 44 (as
best shown in FIG. 6). For example, the horizontally extending
coupling portion 54 of the deck post 50 may be placed over and/or
coupled to the deck mount 48, optionally with mechanical fasteners,
welding techniques, and the like. The left and right side two-piece
assemblies 42, 44 are then arranged within the respective sides of
the deck sill component 46 as shown in FIG. 2 to form the
combination 40 that is shown in FIG. 2. For example, the deck sill
component 46 may be placed over both the coupling portion 54 of the
deck post 50 and the remaining exposed area from the deck mount 48.
The combination 40 from FIG. 2 is then ultimately attached to the
deck of the truck cargo bed 26 and is coupled to a frame component
21 (FIG. 6) using deck post bolts 78. The deck bolts 78 can be used
to couple both the deck sill component 46 and the deck mount 48
directly to the frame 21, for example, such that the deck sill
component 46 is coupled to the respective deck mount 48 and the
vehicle frame 21 with one fastener. This not only reduces the
number of parts, but also reduces the number of connections between
the different parts, which ultimately reduces manufacturing and
associated costs.
[0033] The pillar portion 52 of the rear deck post 50 may be
provided with a plurality of different regions or sections having
different strengths and other properties. For simplicity, FIG. 4
shows the pillar portion 52 as having an upper region 62 and a
lower region 64. It should be understood that the pillar may be
defined with many different regions to serve many different
purposes. In one example, the upper region 62 may be provided with
walls 80 and extending ribs 82, 84 (see, FIG. 7) of a first wall
thickness, or upper wall thickness, while the lower region 64 may
be provided with walls 80 and extending ribs 82, 84 of a second
wall thickness, or lower wall thickness. Based on the strength
requirements and need to address the cantilevered forces from
applied stresses and loads, it may be desirable that the lower wall
thickness be greater than the upper wall thickness. In certain
aspects, it may be desirable that the wall thickness be provided
with a thickness gradient, for example, where the wall thickness
increases in a direction extending from the upper region 62 to the
lower region 64 of the pillar portion 52 of the deck post 50.
Similarly, the upper region 62 of the pillar portion 52 may be
provided with an upper width dimension, and the lower region 64 of
the pillar portion 52 may be provided with a lower width dimension,
where the lower region 64 is wider than the upper region 62. The
horizontally extending coupling portion 54 may be provided with a
substantially U-shaped cross section, configured to mate with an
upper surface of the deck mount 48, as well as to conform with a
shape of the deck sill component 46.
[0034] FIG. 5 is a cross-sectional view of the deck sill component
46 of FIG. 4 taken along the line 5-5. In the various aspects, the
deck sill component 46 has a substantially constant and uniform
cross section along the longitudinally extending length dimension,
and can evenly distribute and transfer an applied force in a
longitudinal direction across a length of the deck sill component
46. The deck sill component 46 may be provided with various
notches, apertures 66, and other shaped portions in order to
accommodate for the use of utility vehicle frame and towing hitch
attachments, for example, without the loss of the various
advantages otherwise discussed herein. As shown in FIG. 5, the deck
sill component 46 may include an upper wall portion 68 and opposing
sidewall portions 70, 72. The sidewall portions 70, 72 can be of
various dimensions. As shown, the outer sidewall portion 72 is
provided with a greater extension than the inner sidewall portion
70, and the inner sidewall portion 70 is shown having an angled
flange 74 extending therefrom. The flange 74 portion may be used
for coupling to the deck mount 48 and the deck post 50, as well as
to other components of the cargo bed 26. In various aspects, the
deck sill component 46 is ultimately disposed underneath a bed
floor 36 of the cargo bed 26. The upper wall portion 68 may be
provided with upward facing ramp features 76 extending across the
length dimension that may provide additional strength and/or
connections to other components such as the bed floor 26. In other
aspects, the reverse configuration may be provided, where there are
downward facing ramp features (not shown).
[0035] FIG. 6 is a side perspective view of an exemplary two-piece
deck post assembly 44 according to various aspects of the present
technology. FIG. 7 is a side plan view of an exemplary rear deck
post 50 illustrating details of an internal cavity 79 defined by
the walls 80 in the pillar portion 52 and having a plurality of
internal web, or rib, features. As noted above, the thickness of
the walls 80 of the pillar portion 52 may vary at different regions
or heights, such as at different locations along the vertical axis
of the pillar portion 52. The strength of the deck posts 50 can be
modified by incorporating various internal ribs, such as laterally
extending ribs 82 and cross-shaped or "X" shaped ribs 84. The
shape, sizes, thicknesses, and specific locations of the ribs 82,
84 within the cavity 79 can be mixed to accommodate an optimization
of mass, performance, and packaging requirements. Notably, the
interior of deck post 50 may need to accommodate various other
features such as wiring and components for tail lights 86 and
components for the tailgate 38.
[0036] The exterior of the deck post 50 similarly may be shaped,
for example, with one or more notched or angled areas 88 to
accommodate D-rings tie downs, or other components of the cargo bed
26 or the vehicle 20. As shown, the deck post 50 may be provided
with side flange walls 90, 92, 94 that may serve as connection
points for other components such as the sidewalls 32, 34 the cargo
bed 36 (shown in FIG. 1), and the like. In one example, the side
wall flange 94 may provide a surface for wire harness connections.
The various surfaces of the flanges 94 may also be used to connect
the deck post 50 and the deck mount 48. Preferably, at least a
portion of the deck posts 50 define walls 96, 98 (or portions
thereof) providing an exterior surface of the cargo bed 26 or the
utility vehicle 20 itself, for example, that is exposed to an
external environment. In other words, the deck post 50 not only
serves as an important structural component, it also provides the
exterior surface, and does not need to be covered by additional
materials. The exterior of the deck post 50 may also define various
apertures or connections points, for example, an aperture 100 for
tailgate connections, an aperture 102 for a tailgate hinge, as well
as apertures for connections such as lamp screws, a tailgate
striker, and the like.
[0037] FIG. 8 is a first side perspective view of an exemplary deck
mount 48, and FIG. 9 is a second side perspective view of the
exemplary deck mount 48, which is rotated about 180 degrees from
the view as shown in FIG. 8. FIG. 10 is yet another perspective
view of the deck mount 48, illustrating the bottom and interior of
the deck mount 48 with its various internal web, or rib features
according to one non-limiting aspect. In various examples, the deck
mount 48 may be a cast metal alloy, as described above, and is
generally provided with a main body portion, 104, a horizontally
extending flange portion 108, and a vertically extending flange
portion 106. The main body 104 may be defined by a top portion 112,
a front side portion 114, a rear side portion 116, and opposing
side portions 118. As shown, one side may also extend a short
distance below the main body 104, depending on the particular
design and how the deck mount 48 is configured to attach to other
components, such as the vehicle frame 21 or brackets. Various
apertures 120 may be defined in the deck mount for fastening
purposes, for example, for coupling to a brace (not shown) to
provide the deck side panel with stiffness. Certain apertures may
be threaded to eliminate the need for nuts, or in certain aspects,
clinch nuts may be used instead of weld nuts. At least one
vertically extending collar 122 may be provided defining an
aperture 123 for receiving the deck bolt 78. The deck bolt aperture
122 may extend a distance from the top 112 of the deck mount, and
further be supported by a plurality of support webs 124. As shown
in FIG. 10, the deck mount 48 may be cast with a plurality of
support ribs 126 within an interior of the main body portion
104.
[0038] The combination of the uniformly shaped deck sill 46 and a
tapered pillar portion 52 of the rear post 50 (or alternatively a
rear post 50 having different regions 62, 64 with different
thicknesses or strengths) is configured to provide a significant
advantage in terms of weight and deflection. For example, the
combined structure has an optimum weight, much lower than
conventional deck sill and post combinations, and provides a
distinct advantage of minimum deflection while withstanding the
cantilevered forces generated due to an applied load. In various
aspects, the pillar portion 52 of each deck post 50 is configured
to exhibit a tapering I-value that is greatest at a lower region
near the horizontally extending coupling portion in order to
minimize any deflection from a force applied to the respective rear
deck post assembly.
[0039] As used herein, the term I-value of a deck post (e.g., beam)
represents the inertia of the deck post to resist bending. This may
also be referred to as the second moment of are or second moment of
inertia. For example, in the field of structural engineering, the
second moment of area of a beam is a property used in the
calculation of the beam's deflection and the calculation of stress
caused by a moment applied to the beam. The planar second moment of
area provides insight into a beam's resistance to bending due to an
applied moment, force, or distributed load perpendicular to its
neutral axis, as a function of its shape. The polar second moment
of area provides insight into a beam's resistance to torsional
deflection, due to an applied moment parallel to its cross-section,
as a function of its shape. This resistance to deflection or
torsion is function of shape, and not due to a beam's material
stiffness, or elastic modulus.
[0040] The foregoing description is provided for purposes of
illustration and description and is in no way intended to limit the
disclosure, its application, or uses. It is not intended to be
exhaustive or to limit the disclosure. Individual elements or
features of a particular embodiment are generally not limited to
that particular embodiment, but, where applicable, are
interchangeable and can be used in a selected embodiment, even if
not specifically shown or described. The same may also be varied in
many ways. Such variations should not be regarded as a departure
from the disclosure, and all such modifications are intended to be
included within the scope of the disclosure.
[0041] As used herein, the phrase at least one of A, B, and C
should be construed to mean a logical (A or B or C), using a
non-exclusive logical "or." It should be understood that the
various steps within a method may be executed in different order
without altering the principles of the present disclosure.
Disclosure of ranges includes disclosure of all ranges and
subdivided ranges within the entire range, including the
endpoints.
[0042] The headings (such as "Background" and "Summary") and
sub-headings used herein are intended only for general organization
of topics within the present disclosure, and are not intended to
limit the disclosure of the technology or any aspect thereof. The
recitation of multiple embodiments having stated features is not
intended to exclude other embodiments having additional features,
or other embodiments incorporating different combinations of the
stated features.
[0043] As used herein, the terms "comprise" and "include" and their
variants are intended to be non-limiting, such that recitation of
items in succession or a list is not to the exclusion of other like
items that may also be useful in the devices and methods of this
technology. Similarly, the terms "can" and "may" and their variants
are intended to be non-limiting, such that recitation that an
embodiment can or may comprise certain elements or features does
not exclude other embodiments of the present technology that do not
contain those elements or features.
[0044] The broad teachings of the present disclosure can be
implemented in a variety of forms. Therefore, while this disclosure
includes particular examples, the true scope of the disclosure
should not be so limited since other modifications will become
apparent to the skilled practitioner upon a study of the
specification and the following claims. Reference herein to one
aspect, or various aspects means that a particular feature,
structure, or characteristic described in connection with an
embodiment or particular system is included in at least one
embodiment or aspect. The appearances of the phrase "in one aspect"
(or variations thereof) are not necessarily referring to the same
aspect or embodiment. It should be also understood that the various
method steps discussed herein do not have to be carried out in the
same order as depicted, and not each method step is required in
each aspect or embodiment.
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