AU2019101309A4 - Expandable and convertible tailgate apparatus for a vehicle - Google Patents

Abstract

An expandable and convertible tailgate apparatus for a vehicle including utility-backed campers and canopies, vans, troop carriers, convertible sports utilities, RV's, 4x4's, trucks, event trailers and caravans or like vehicles with either compatible 5 adjustable pop-top or fixed high-top roofs and has, a cover panel and a floor panel which pivot between vertical positions adjacent the rear end, or side edge, and horizontal positions outside the vehicle body, and inter-connected rear wall sections which unfold to stand vertically between the deployed floor and cover panels, thus forming an extension having a roof, rear wall and a floor. A slidable means of 10 articulation and vertical supports facilitate compatibility with adjustable pop-top roofs. Separate components comprising a side door, and a side wall fully enclose the additional space. Conversion into a handy split tailgate configuration, by removal of the rear wall sections, is herein described for both roof styles. F I G(RE16

Description

EXPANDABLE AND CONVERTIBLE TAILGATE APPARATUS FOR A VEHICLE

FIELD OF THE INVENTION

The present disclosure relates to vehicles with an adjustable pop-top roof or a fixed high-top roof, such as, but not limited to, utility-backed campers and canopies, vans, troop carriers, convertible sports utilities, RV’s, 4x4’s, trucks, event trailers and caravans or like vehicles, and particularly to an expandable tailgate that may convert into a split tailgate for the same.

BACKGROUND OF THE INVENTION

Several folding extensions for utility-backed campers are known to exist in the prior art and have rigid fold-down floors or flip-over roofs that draw attached flexible fabric from internal stowage to form a tent-like additional space. Operation may be by hand winch, gas strut, linear actuator with electric motor and remote controller, or a combination thereof. Many require the user to complete manual erection of the fabric component. Some existing systems suspend a high-set floor area above or beside the host vehicle while others extend, by pivotal action, fully to ground level. The Applicant is not aware of any existing system that may convert into another configuration.

Limitations of the folding extensions described above include, poor stability, limited insulation and inability to secure the rear of the vehicle. Set-up and stowage typically involve multiple, and often simultaneous tasks. A winch handle may need to be left during winding to push a solid component through the top dead-centre point of balance, or to tuck in protruding fabric as the extension closes. At such times, the ratchet wheel pawl must be engaged to prevent backwards free spin of the handle and unexpected direction change and travel speed of the load. Exposed moving parts and pinch points on winches require careful operation and a jammed mechanism or fouled line may take significant time to rectify. A remote controller may be misplaced or damaged and a flat battery would render the unit inoperable, thereby making a back-up manual over-ride system essential. The operator may need to work in poor light under collapsed material to place or remove support stays during erection and stowage of the fabric component. High-set sleeping areas on suspended floors may require ladder access through a cramped, low clearance entrance. Extensions with a rear-end entrance may lack a hand rail when stairs are set at right-angles to the camper body. Ergonomically challenging mechanisms, procedures and access may increase the risk of personal injury. Flexible fabric components typically fold into the interior of the camper body, on top of living and sleeping areas thereby making protective covers necessary for internal wares. Furthermore, the whole unit may require airing to prevent the formation of mould after stowage during wet weather. Lastly, folding extensions with set configurations limit versatility of the host vehicle and thus forfeit use in other applications.

Another type of folding extension, designed to attach to a side wall of a utilitybacked camper, forms rigid additional space from metal panels stowed in slots in a floor panel. Side and rear wall panels slide outwards, pivot upwards and unfold in a series of steps to engage with a swing-up roof panel.

Limitations of the folding extension described above include jamming of the sliding components, should any damage or distortion occur, and a complicated deployment that requires the operator to perform a multi-step sequence.

Vans, troop carriers and convertible sports utilities may be fitted with an adjustable pop-top roof, or a fixed high-top roof, to create extra head room within the vehicle. A simple flexible fabric extension has been designed to hang from a single lift-up rear door, and bolt-on camper modules with an adjustable pop-top roof have been designed for convertible sports utilities.

Limitations of flexible fabric extensions have been described earlier. Vehicles with adjustable pop-top or fixed high-top roofs may be height restricted at the pop-top sill and/or the doorframe header, thus obliging the operator to duck during entry and exit from the rear of the vehicle. Double swing-out rear doors create obstacles to manoeuvre around when open and may unexpectedly shut in windy conditions. Both single lift-up and double swing-out doors create large openings that are difficult to screen and must be shut when security is required. These vehicle types are relatively small for camping and interior living space is often minimal.

Multiple aluminium and fibreglass service canopies for tradespeople have been designed for tray-backed utility vehicles. Options available for well-bodied utility vehicles are often limited to simple, low profile fibreglass canopies.

Limitations of service canopies include poor versatility of the host vehicle as most, if not all, of the utility area is occupied by a canopy that does not extend to create additional space. Thus, service canopies cannot readily be used for camping or other applications.

It should be appreciated that any discussion of the prior art throughout the specification is included solely for the purpose of providing a context for the present invention and should in no way be considered as an admission that such prior art was widely known or formed part of the common general knowledge in the field as it existed before the priority date of the application.

It is therefore an object of the illustrated embodiments to provide an expandable and convertible tailgate apparatus for a vehicle that in one form may be lockable. Other objects of the illustrated embodiments are to overcome at least some of the aforementioned problems, or at least provide the public with a useful alternative. The foregoing objects should not necessarily be considered as cumulative and various aspects of the invention may fulfil one or more of the above objects.

The reader should appreciate that the terms vehicle, utility body, vehicle body or similar, used throughout the specification and claims are interchangeable and may relate to any vehicle, including but not limited to, campers, canopies, RV’s, 4x4’s, vans, troop carriers, convertible sports utilities, trucks, event trailers and caravans.

SUMMARY OF THE INVENTION

In one aspect of the invention, but not necessarily the broadest or only aspect, there is proposed an expandable and convertible tailgate apparatus, or otherwise referred to as a folding extension/split tailgate, for a vehicle, comprising: a cover panel hingedly connected to a roof of the vehicle or a frame attached thereto; a floor panel hingedly connected to a floor of the vehicle or a frame attached thereto; a lower rear wall section both fixedly and detachedly connected to the floor panel and generally perpendicular thereto;

an upper rear wall section hingedly connected to the lower rear wall section and slidably and/or pivotably engaging the cover panel, and wherein the expandable and convertible tailgate apparatus being movable between a retracted arrangement, whereby the lower and upper rear wall sections extend inwardly of an internal space of the vehicle and an expanded arrangement, wherein the cover panel and floor panel extend outwardly from the vehicle, and the upper and lower rear wall sections are vertically coplanar, to thereby provide an extension to the internal space of the vehicle, or said upper and lower rear wall sections are removed to convert into a split tailgate configuration.

In one form the roof of the vehicle is fixed. In another form the roof of the vehicle is reversibly adjustable upwardly, also known as a pop-top configuration.

Preferably side wall portions may be connectable between the vertically coplanar upper and lower rear wall sections, cover panel, floor panel and a suitably strong rear edge or side edge of the vehicle, or hingedly connected to and folded upon the upper and lower rear wall sections, or hingedly connected to and folded upon the rear edge, or side edge, of the host vehicle body whereby the extension space is enclosable.

The side wall portions may include window/s, screen/s, or permit access by way of a door. One of the side wall portions may therefore comprise a frame connectable to, or hinged upon, the vertically coplanar upper and lower rear wall sections, cover panel, floor panel and a suitably strong rear edge or side edge of the vehicle, which is configured to hingedly retain a door panel.

The upper and lower rear wall sections, cover panel, and floor panel are preferably generally rigid. The side wall portions may be either generally rigid or constructed from a flexible material, such as canvas, or be a combination thereof.

In accordance with a broad aspect of this invention there is provided a folding extension/split tailgate apparatus for vehicle bodies including but not limited to, utility backed campers, canopies and bolt-on camper modules with a compatible adjustable pop-top roof. The compatible, adjustable pop-top roof extends to the sides or adjacent thereof and rear of the host vehicle body and reversibly expands vertically in a horizontal plane. An attached flexible fabric sleeve preferably has three sides and is open across the rear.

A cover panel is preferably adjustably connected or articulated to an upper rear wall section which is preferably hingedly attached to a lower rear wall section. The lower rear wall section is preferably detachably fixed in turn, to a floor panel. The panels and sections, as described above, preferably stow and deploy simultaneously as inter-connected components. Separate components comprising a set of stairs, vertical supports, a side door and a side wall stow independently and may be attached after the inter-connected components have been deployed.

The cover panel is preferably hinged to the end of the adjustable pop-top roof and the floor panel is preferably hinged to the vehicle body floor. When the pop-top roof is retracted the cover panel is preferably positioned along a generally vertical plane and may be configured to partially overlay the floor panel also in a generally vertical plane to thereby form a vertically enclosed rear end. The lower rear wall section is preferably fixed by detachable right-angled brackets, to the opposite edge of the floor panel. Thus, the lower rear wall section and floor panel move together in reciprocal fashion. As one moves from a vertical orientation into a horizontal orientation, the other moves from a horizontal orientation into a vertical orientation, and vice versa. In stowed mode the lower rear wall section protrudes horizontally into a cavity or internal space of the vehicle body. The edge of the lower rear wall section opposite the floor panel is preferably attached by a continuous hinge or hinges to the upper rear wall section. The hinge or hinges permit both upper and lower rear wall sections to fold flat together within or extending into the cavity or internal space of the vehicle body. The upper and lower rear wall sections are also preferably positionable in a generally vertical plane, with one atop the other, outside the vehicle body. As the lower rear wall section moves from a horizontal orientation into a vertical orientation, or vice versa, the upper rear wall section moves in a similar fashion. The opposite corners of the upper rear wall section engage the cover panel by means of mounted riding pins, which seat in respective track channels in or on the sides of the cover panel. This configuration allows the cover panel to slide generally vertically over the static riding pins as the pop-top roof expands until removable stoppers, which form blind ends at the bottom of the respective track channels, abut the riding pins. Thereby, the leading edge of the upper rear wall section lifts as the cover panel continues to move vertically upwards. Thereafter, the riding pins may act as push points between the upper rear wall section and cover panel.

It should be understood by the skilled addressee that in the present form of the invention, the operator may perform two manual manoeuvres in order to raise the pop-top roof and deploy the inter-connected components. First, the operator pushes the cover panel vertically upwards. Three things occur with this manoeuvre. The cover panel disengages from the floor panel, the pop-top roof expands, and the leading edge of the upper rear wall section is drawn upwards via the riding pins.

Second, the operator pulls the floor panel out and down through approximately 90 degrees to a generally horizontal position. Likewise, three things occur with this manoeuvre. The lower rear wall section moves from horizontal to a vertical orientation, the upper rear wall section unfolds at the continuous hinge to be positioned generally vertically atop the lower rear wall section, and the outer edge of the cover panel is pushed from vertical to a horizontal orientation via the riding pins, as the rear wall sections emerge from within the vehicle body. Thus, a simple two step “push/pull” manual operation raises the pop-top roof and forms an expandable portion outside the vehicle body, which has a floor, a rear wall and a roof.

Next, the operator may attach the separately stowed components. The stairs connect to the floor panel, the vertical supports preferably brace the rear corners of the extended pop-top roof and secure the free ends of the flexible fabric sleeve, the side door may slot into a passenger side void, and the side wall may slot into a driver side void. Alternatively, the side door and/or side wall may hinge to and fold upon the rear wall sections or the rear edge, or side edge, of the utility body.

In another aspect of this invention there is provided a folding extension/split tailgate apparatus for vehicles including but not limited to, troop carriers and vans with a compatible adjustable pop-top roof by means of a “U” shaped frame that replaces the rear door/s and header, and provides attachment points for the floor panel. The inter-connected components, means of articulation, separate components, and method of operation remain generally the same as described in the immediately preceding aspect.

In another aspect of this invention there is provided a folding extension/split tailgate apparatus for vehicles including but not limited to, vans and troop carriers with a fixed high-top roof by means of a rectangle shaped frame that replaces the extended height rear doors, or the header and standard height rear doors, and provides attachment points for the cover and floor panels. The inter-connected folded components and side wall portions remain similar to that described in the immediately preceding aspect, however, the track channels remain static with the riding pins during deployment of the inter-connected components. If preferred, hinges with removable pins may be substituted. Accordingly, vertical supports are not required.

In this embodiment of the invention, the operator performs one manual manoeuvre in order to deploy the interconnected components, wherein the floor panel is pulled down to horizontal. Thus, a simple one step manual operation forms an expandable portion outside the vehicle body, which has a floor, a rear wall, and a roof. The stairs, side door and side wall are generally the same as described in the immediately preceding aspects of the invention.

Preferably the folding extension converts into a split tailgate for vehicles with either a compatible adjustable pop-top or fixed high-top roof, by removal of the upper and lower rear wall sections. In the split tailgate configuration, the floor and cover panels are unencumbered by the rear wall sections and therefore, may operate independently of each other. Moreover, the vehicle body interior is free of the separately stowed components and may be utilised for more varied purposes.

Another aspect of the present invention provides a folding extension/split tailgate that may be fitted to the rear or side of a vehicle including but not limited to, trucks, event trailers and caravans by means of a frame that provides attachment points for the cover and floor panels. The frame is suitably engineered to provide structural integrity at the rear or side of the host vehicle. The invention may be used in split tailgate mode as an open veranda, the upper and lower rear wall sections may provide privacy screening or weather protection, and the side door and side wall may partially or fully enclose the extension as desired. The inter-connected components and side wall portions remain similar to that described for a fixed hightop van. Should enlargement of the inter-connected components be desired, mechanical or electric hydraulic operation may become necessary.

In still another aspect of the invention there is provided a method of expanding an internal space of a vehicle, including the steps of: providing an expandable and convertible tailgate apparatus for a vehicle, comprising a cover panel hingedly connectable to a roof of the vehicle or a frame attached thereto, a floor panel hingedly connectable to a floor of the vehicle or a frame attached thereto, a lower rear wall section both fixedly and detachably connectable to the floor panel and generally perpendicular thereto, an upper rear wall section hingedly connectable to the lower rear wall section, and slidably and/or pivotably engageable with the cover panel;

attaching the expandable and convertible tailgate apparatus to the vehicle; moving the expandable and convertible tailgate apparatus from the folded retracted arrangement, wherein the lower and upper rear wall sections extend inwardly of an internal space of the vehicle, and the unfolded expanded arrangement wherein the cover panel and floor panel extend outwardly from the vehicle, and the upper and lower rear wall sections are positioned in the generally vertical coplanar arrangement, to thereby provide an extension to the internal space of the vehicle.

The above method including the intermediate steps or step, of: pushing the cover panel in the generally vertical direction, wherein the pop-top roof expands, the track channels in the cover panel sides move over the static riding pins, the removable stoppers at the bottom of the track channels abut the riding pins and the riding pins thereafter, lift the leading edge of the upper rear wall section, and or: pulling the floor panel from vertical to the generally horizontal arrangement, thereby moving the lower rear wall section, to which it is fixedly connected, into the generally vertical arrangement, and thereby moving the upper rear wall section, to which it is hingedly connected, into the generally vertical coplanar arrangement, and thereby moving the cover panel, to which it is slidably and/or pivotably engaged, into the generally horizontal arrangement.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate implementations of the invention and, together with the description and claims, serve to explain the advantages and principles of the invention. In the drawings,

Figure 1 is a side view of the folding extension/split tailgate apparatus in the stowed condition with the cover panel overlaying the floor panel and attached to a utility body with a compatible adjustable pop-top roof;

Figure 2 is a rear view of the folding extension/split tailgate apparatus of Fig. 1;

Figure 3 is an enlarged partial view of the cover panel overlaying the floor panel and a track channel and stopper, shown in broken lines, mounted on the inner aspect of the cover panel side;

Figure 4 is a side view of the folding extension/split tailgate apparatus of Fig. 1, with the inter-connected folded components, being the upper and lower rear wall sections shown in broken lines;

	Figure 5	is an enlarged partial sectional view taken along the line 5--5 of Fig. 2 illustrating the top of the track channel at the level of the riding pin when the folding extension/split tailgate is in the stowed condition;
5	Figure 6	is an enlargement of a mounting block on the upper surface of the upper rear wall section, a track channel in a side of the cover panel, a removable stopper at the bottom/far end of the track channel, and a riding pin connecting the upper rear wall section to the cover panel;
10	Figure 7	is a side view of the folding extension/split tailgate apparatus with the floor and cover panels disengaged, the pop-top roof expanded with scissor lift assistance, the flexible fabric sleeve drawn taut, the upper rear wall section lifted at the leading edge, and the bottom of the track channel at the level of the riding pin shown in broken lines;
	Figure 8	is a rear view of the folding extension/split tailgate apparatus of Fig. 7 with the grab rail visible in a horizontal recess in the floor panel;
15	Figure 9	is a rear view of the folding extension/split tailgate apparatus during deployment of the inter-connected components with the floor panel approaching horizontal, the cover panel pivoted upwards, the upper and lower rear wall sections approaching vertical, and the expanded pop-top roof shown in broken lines;
20	Figure 10	is a side view of the folding extension/split tailgate apparatus of Fig. 9;
	Figure 11	is a side view of the folding extension/split tailgate apparatus with the inter-connected components deployed, a vertical support completing a perimeter around a void, and the stairs attached;
25	Figure 12	is an enlarged side view of the vertical support of Fig. 11 with a material flap and rubber seal attached;
	Figure 13	is the outer aspect of the side door and frame for use with the folding extension/split tailgate apparatus;
	Figure 14	is the inner aspect of the side wall and frame for use with the folding extension/split tailgate apparatus;

Figure 15	is a side view of the folding extension/split tailgate apparatus in the fully deployed condition with the side door of Fig.13 attached;
Figure 16	is a rear perspective view of the folding extension/split tailgate apparatus of Fig. 15;
Figure 17	is a rear view of the folding extension/split tailgate apparatus of Fig. 16;
Figure 18	is a side view of the folding extension/split tailgate apparatus in the stowed condition and attached by a “U” shaped frame to a troop carrier with a compatible adjustable pop-top roof with the interconnected folded components shown in broken lines;
Figure 19	is a rear view of the “U” shaped frame attached to a troop carrier with a compatible adjustable pop-top roof in the retracted condition;
Figure 20	is a side view of the “U” shaped frame of Fig. 18 illustrated in relation to the host vehicle;
Figure 21	is a side view of the folding extension/split tailgate apparatus in the fully deployed condition attached by the “U” shaped frame to a troop carrier with a compatible adjustable pop-top roof;
Figure 22	is a side view of the folding extension/split tailgate apparatus in the stowed condition attached by a rectangle shaped frame to a van with a fixed high-top roof, with the inter-connected folded components shown in broken lines;
Figure 23	is a rear view of the rectangle shaped frame attached to a van with a fixed high-top roof;
Figure 24	is a side view of the folding extension/split tailgate apparatus in the fully deployed condition attached by the rectangle shaped frame to a van with a fixed high-top roof;
Figure 25	is a side view of the split tailgate in the deployed condition with the cover panel supported by a gas strut and attached to a utility body with a retracted pop-top roof;

Figure 26 illustrates schematically a typical means for converting the folding extension into a split tailgate;

Figure 27 is a side view of the removed upper and lower rear wall sections of Fig. 26; and

Figure 28 is a rear view of the split tailgate with the floor and cover panels vertical, prior to lowering the expanded pop-top roof.

DETAILED DESCRIPTION OF THE ILLUSTRATED AND EXEMPLIFIED EMBODIMENTS

Similar reference characters indicate corresponding parts throughout the drawings. Dimensions of certain parts shown in the drawings may have been modified and/or exaggerated for the purposes of clarity or illustration.

Referring to the drawings for a more detailed description, there is illustrated an expandable and convertible tailgate apparatus for a vehicle, demonstrating by way of examples, arrangements in which the principles of the present invention may be employed.

Referring to Figures 1 and 2, there is illustrated one embodiment of an expandable and convertible tailgate apparatus, or otherwise referred to as a folding extension/split tailgate 10 for a vehicle and is generally designated in the stowed arrangement and attached to a utility body 11 with a compatible adjustable pop-top roof 12 with a 600mm lift. Since a utility body 11 and an adjustable pop-top roof 12 are conventional items they have been indicated semi-schematically in the figures and will not be discussed in detail.

A suitably strong floor panel 13 is attached to the utility body floor 14 with hinges 15 and a cover panel 16 is attached to the adjustable pop-top roof 12 with suitable hinges 15a. The skilled addressee will appreciate that hinges 15 attached to the floor panel 13 are sufficiently strong as to carry the weight of a user when the apparatus is in the expanded arrangement. The panels may be constructed from light weight and durable aluminium. In the stowed arrangement of the folding extension/split tailgate apparatus 10, the slightly deeper cover panel 16 partially overlays the floor panel 13 by approximately half, to form a vertically enclosed rear end. Over-centre fasteners 17 and corresponding catches 17a clamp the cover panel against metal strips 18 set at right angles to the utility body 11 rear walls 19, 20. Toggle fasteners 21 and corresponding catches 21a secure the adjustable pop-top roof 12 to the utility body side walls 22. Other conventional means of fastening, which perform in a similar manner, may be employed. Handles 23 mounted on the cover panel 16 provide the operator with grip points to push the cover panel 16 vertically upwards. A suitably strong metal stop bar 24 with contact points 25, mounted on the utility body sub frame 26, provides protection against collision damage in travel mode and supports the floor panel 13 in deployed mode. A gas strut (not shown) may be mounted under the utility body floor to prevent over rapid deployment of the floor panel if desired. A hand rail 27 is mounted on rear wall 19 and latch 28, mounted on rear wall 20, corresponds with tab 29 to secure the floor panel 13 closed when the invention is in split tailgate mode. A slotted stair dock 30 secured to the floor panel 13 is an attachment point for stairs (not shown in the present figure). Side recesses 31 in the floor panel 13 accommodate the sides 32 of the cover panel 16 and thus achieve a compact rear-end profile.

As illustrated in Figure 3, a side 32 of the cover panel 16 is accommodated in a side recess 31 in the floor panel 13. A track channel 33, illustrated in broken lines, is riveted (obscured in the present figure), or otherwise affixed, to the inner aspect 32a of side 32. The bottom end of the track channel 33 is preferably closed with a removable metal stopper 34 held in place with a suitable bolt 35 (shown in relation to the track channel and stopper). The track channel 33 is of such length to correlate with the amount of overlay between the floor and cover panels 13, 16 respectively, when the invention is in stowed mode. The reader will appreciate that the mirror image configuration applies to the opposite side of the cover panel.

The inter-connected folded components, shown in broken lines in Figure 4, stow inside the utility body 11 and comprise a lower rear wall section 36 and an upper rear wall section 37 foldable along a continuous hinge 38. The lower rear wall section 36 is fixed to the floor panel 13 by detachable right-angled brackets (concealed in the present figure), and the upper rear wall section 37 is both slidably and pivotably connected to the cover panel 16. In the enlargement of Figure 5, the upper rear wall section 37 is connected to the cover panel 16 by means of a mounting block 39 and riding pin 40 seated in the track channel 33 in the cover panel 16 side 32. It is noted that the top of the track channel 33 is level with the riding pin 40 when the cover panel 16 partially overlays the floor panel 13 in stowed mode.

Right-angled aluminium strips 41 with pinch-weld rubber extrusions 42 are attached to the outer edges of the upper and lower rear wall sections 37 and 36, respectively. Furthermore, the upper rear wall section 37 is slightly longer than the lower rear wall section 36 to account for the depth of the cover panel 16.

The means to connect the upper rear wall section 37 to the cover panel 16 is shown enlarged in Figure 6. A mounting block 39 is attached by bolts 35a, 35b with metal washers 43, 43a to a top corner of the upper rear wall section 37 (semi cut away in the present figure). A riding pin 40 is held in the mounting block 39 by lock nuts 44, 44a, flexible spacers 45, and metal washers 43b. The head 46 of the riding pin 40 is corralled inside guides 47 on the track channel 33. The track channel 33 is secured by rivets 48 to the cover panel 16 side 32 (semi cut away). A metal washer 43c, preferably square, prevents fretting of frictional surfaces and a removable stopper 34 seals the bottom end of the track channel 33. Other similar components may be employed to achieve the same purpose. The means of connection applies in mirror image on the opposite top corner of the upper rear wall section and the opposite side of the cover panel.

On initial deployment of the cover panel 16 (Figure 7), fasteners 17, 17a, 21 and 21a are released and the cover panel 16 is manually pushed vertically upwards using the handles 23. With this manoeuvre, the adjustable pop-top roof 12 expands 600mm with scissor lift 49 assistance. Further lift assistance may be gained by mounting gas struts (not shown) within the utility body side walls if desired. The flexible fabric sleeve 50 is drawn taut with a free end 51 visible. Bottom section 54 and top section 54a of a detachable right-angled bracket are visible. As the cover panel 16 disengages from the floor panel 13, the track channels 33 slide over the static riding pins 40 to the removable stoppers (obscured in the present figure). The removable stoppers abut the riding pins 40 and thereby lift the leading edge of the upper rear wall section 37 approximately 200mm. The riding pins may, thereafter, act as push points between the upper rear wall section and the cover panel. Thus, the adjustable pop-top roof expands with manual movement of the cover panel 16.

Figure 8 illustrates the cover panel 16 with handles 23 disengaged from the floor panel 13, the lifted upper rear wall section 37, the grab rail 52 in the horizontal recess 53, the bottom sections 54, 55 of the detachable right-angled brackets, rubber seals 56, and the metal strips 18.

Referring to Figure 9, the operator uses the grab rail 52 to pull the floor panel 13 outwards and downwards towards horizontal. The effects of this manual manoeuvre are illustrated in Figures 9 and 10. The fixed lower rear wall section 36 moves from a horizontal orientation towards a vertical position, the continuous hinge 38 unfolds the upper rear wall section 37 from a horizontal orientation towards a vertical position, and the outer edge of the cover panel 16 swings from a vertical orientation towards a horizontal position as the rear wall sections 36, 37 emerge from within the vehicle body. Thus, the inter-connected components expand simultaneously, as one unit, with manual movement of the floor panel 13. The expanded pop-top roof 12 and a free end 51 of the flexible fabric sleeve 50 are visible. In Figure 9, bottom sections 54, 55 and top sections 54a, 55a of the detachable right-angled brackets, bolts 35c, 35d, rubber seals 56, and metal strips 18 are visible. Furthermore, track channels 33 in the cover panel 16 sides 32 and mounting blocks 39 on the upper rear wall section 37 are joined by the concealed riding pins.

In Figure 11, the inter-connected components are disposed in the deployed position wherein, the floor panel 13 in a horizontal position, is supported by the stop bar 24 and contact points 25, and the cover panel 16 in a horizontal position, is supported by the vertical upper and lower rear wall sections 37, 36, respectively. Next the operator attaches a set of stairs 57 into stair dock 30 to gain access to the separately stowed components. The separate components have not been illustrated in stowage due to the multiplicity of possible configurations, dependent upon the preferred interior layout of the utility body 11. Likewise, alternate configurations of the side wall portions have not been illustrated in the figures. The operator places two metal hollow section vertical supports 58 (one shown enlarged in Figure 12) into the utility body 11 rear corners to brace the expanded pop-top roof 12 and to complete a perimeter around void 59. Flexible material flaps 60, attached to the side face of the vertical support 58 with rivets, glue or sail track (not shown), affix to the flexible fabric sleeve 50 with hook and pile tape, lashing or similar method (not shown). Rubber seals 56 (Figure 12), attached to the rear face of the vertical support 58, form a continuation of seals 56 shown in Figures 8 and 9.

Referring to Figures 11,13 and 14, a side door 61 has a frame 62 of such size to occupy void 59 on the passenger side, and a side wall 63 has a frame 64 of such size to occupy void 59 on the driver side. The rear-facing long edge of frames

62, 64 are fitted with “C” section channel 65. Aluminium is the preferred build material and the frames may be furnished with sheeting or security mesh. Windows with fly screens, vents, shutters and insulation may be incorporated as desired by the owner or manufacturer. Flexible material or fabric may be used instead of a door and/or side wall if security is not an issue.

In another embodiment, the sidewall portions may be bi-fold to stow shorter and/or hingedly connected to, and folded upon, the upper and lower rear wall sections, or hingedly connected to, and folded upon the rear edge, or side edge, of the utility body.

The folding extension/split tailgate apparatus 10 is shown in the fully deployed condition attached to a utility body 11 in Figures 15 and 16. A vertical support 58 braces the expanded pop-top roof 12, the material flap 60 secures the flexible fabric sleeve 50, the side door 61 occupies the passenger side void and the stairs 57 provide access. The forward edge of the side door 61 frame 62 is secured to the metal strips 18 with slide latches (not shown). The “C” section channel 65 slots over the pinch weld rubber extrusion (concealed in the present figure) on the right-angled aluminium strips 41 on the upper and lower rear wall sections 37, 36 respectively. The side wall (obscured in the present figure) is retained in the same manner. Weather sealant, in the form of rubbers, flaps or flexible material gussets, may be incorporated around hinges 15 and 15a (Figure 15). The top sections 54a, 55a of the detachable right-angled brackets are secured with bolts 35c to the bottom sections 54, 55 on the floor panel 13, and secured with bolts 35d to the lower rear wall section 36, best illustrated in Figure 16. The rearview in Figure 17 illustrates latch 28 on rear wall 20, and tab 29 on the floor panel 13.

Aluminium in one embodiment is the preferred primary material of the build, due to its lightness and durability. Parameters for the inter-connected components may be approximated as follows; the length of the floor and cover panels depend on the preferred width of the side voids; the height of the rear wall sections depend on the combined heights of the utility body interior and the expanded pop-top roof. The amount of overlay and the corresponding track channel length, is determined by the length of the floor and cover panels and the height of the utility body with the pop-top roof retracted.

The folding extension/split tailgate apparatus of the present embodiment provides approximately 800mm of horizontal space and 600mm of vertical space that may be used for cooking, or storage to de-clutter the interior, or hang wet weather gear, or to place a portable toilet, or pet bedding etc. A deck chair and occupant may be accommodated without restricting access to the interior of the vehicle. Head height is continuous with the interior of the expanded pop-top roof. The invention provides a useful addition to a utility body that may be used for, but not limited to, remote site work, transport pilot services, recreational camping or similar pursuits.

To stow the folding extension/split tailgate apparatus 10, the reader should initially refer to Figure 15. Remove the side door 61 and side wall (obscured in the present figure); free the material flaps 60 from the flexible fabric sleeve 50 and remove the vertical supports 58. An internal or external elastic band arrangement (not shown) may be utilised to ensure the flexible fabric sleeve 50 folds neatly inward. Remove the stairs 57 and stow with 61,58 and the side wall in the configuration dictated by the interior layout of the utility body 11. Refer to Figure 9. Use the grab rail 52 to manually swing the floor panel 13 up through approximately 90 degrees towards vertical. The upper and lower rear walls sections 37, 36 respectively, simultaneously fold together along the continuous hinge 38 and the cover panel 16 pivots down to vertical as shown in Figure 8. Next, pull down vertically on handles 23 to overlay the floor panel 13, as shown in Figure 2. The pop-top roof 12 simultaneously retracts. Lastly, secure fasteners 17, 17a, 21 and 21a in preparation fortravel mode, as shown in Figure 1.

The invention may be attached to vehicles such as troop carriers and vans with a compatible adjustable pop-top roof. In an embodiment shown in Figure 18, the folding extension/split tailgate apparatus 10 is attached to a troop carrier 66 with a compatible adjustable pop-top roof 12. A suitably strong “U” shaped frame 67, preferably made of aluminium, restores structural integrity to the rear of the vehicle after removal of the standard rear doors and header. The cover panel 16 is attached by hinges 15b to the adjustable pop-top roof 12 and the floor panel 13 is attached by hinges (obscured in the present figure) to the “U” shaped frame 67. The interconnected folded upper and lower rear wall sections 37, 36, respectively, stow inside the troop carrier 66, as illustrated in broken lines.

Referring to Figure 19, the “U” shaped frame 67 has a base 68 and sides 69, 70 fabricated in a manner compatible with the internal perimeter at the rear of the troop carrier 66, and attached thereto by bolts (not shown). Hinges 15c on base 68 provide attachment and pivot points for the floor panel (removed for clarity), and rubber seals 56 provide dust and weather tightness. The adjustable pop-top roof 12 is retracted and the flexible material sleeve 50 is slack. Figure 20 illustrates bolt holes 71 in side 69 of the “U” shaped frame 67.

In Figure 21, the folding extension/split tailgate apparatus 10 is shown fully deployed and attached by the “U” shaped frame 67 to a troop carrier 66 with an expanded pop-top roof 12. Components of the invention including, but not limited to, the floor and cover panels 13,16 respectively; the upper and lower rear wall sections 37, 36 respectively; the riding pins and track channels (concealed in the present figure); the side door 61; the side wall (concealed in the present figure); the vertical supports 58 with material flaps 60; the stop bar 24 with contact points 25; and the stairs 57, and the method of operation remain generally the same as described in the immediately preceding embodiment.

The invention may be attached to vehicles such as vans and troop carriers with a fixed high-top roof. In an embodiment shown in Figure 22, a folding extension/split tailgate apparatus 10 is attached to a van 72 with a fixed high-top roof 73. A suitably strong rectangle shaped frame 74, preferably made of aluminium, restores structural integrity to the rear of the vehicle after removal of the rear doors and header, if present. The cover panel 16 is attached to the rectangle shaped frame 74 with suitable hinges 15d. The upper rear wall section 37 is pivotably connected to the cover panel 16 with a similar track channel/riding pin arrangement (obscured in the present figure) as afore described. However, the track channels need only be of such length to accommodate a riding pin and stopper. Hinges with removable pins may be substituted. Accordingly, there is no requirement for vertical supports in the present embodiment. An extension 75 approximately 200mm long on the end of the cover panel 16 bridges a gap above the floor panel 13 and provides enough overlay to create a dust and weather seal. The grab rail 52 on the floor panel 13 remains exposed and therefore need not be set in a horizontal recess. The inter-connected folded upper and lower rear wall sections 37, 36 respectively, stow inside the van 72, however upper rear wall section 37 is already lifted at the leading edge due to the height of the fixed high-top roof 73.

Referring to Figure 23, the rectangle shaped frame 74 has a top 76, sides 77, 78 and a base 79 fabricated in a manner compatible with the internal perimeter at the rear of the van 72, and attached thereto by bolts (not shown). Hinges 15e on base 79 provide attachment and pivot points for the floor panel (removed for clarity) and rubber seals 56 provide dust and weather tightness.

In Figure 24, the folding extension/split tailgate apparatus 10 is shown fully deployed and attached by the rectangle shaped frame 74 to a van 72 with a fixed high-top roof 73. Components of the invention including, but not limited to, the upper and lower rear wall sections 37, 36 respectively; the side door 61; the side wall (obscured in the present figure); the stop bar 24 with contact points 25; and the stairs 57, remain generally the same as previously described. Variations to the floor and cover panels 13, 16 respectively, have been discussed.

To deploy the inter-connected components, the operator performs one manual manoeuvre wherein the floor panel is pulled down to horizontal. This manoeuvre draws the rear wall sections from the interior of the van and moves the cover panel to the horizontal position. The separate components attach in generally the same manner as previously described.

A particular advantage of one embodiment of the invention is the split tailgate feature. Referring to Figure 25, a deployed split tailgate is generally depicted at 10a and attached, in this example, to a utility body 11 with a retracted pop-top roof 12 secured by toggle fasteners 21,21a. It is noted that the upper and lower rear wall sections have been removed. The cover panel 16 is supported by gas strut 80 (one of two shown) attached to a bracket 81 on the cover panel 16 side 32 and a bracket (obscured) on metal strip 18. The floor panel 13 is supported by the stop bar 24 and contact points 25.

In split tailgate mode the floor and cover panels operate independently of each other and rear access is unencumbered by the inter-connected folded components. Furthermore, the utility body interior is free of the separately stowed components. Thus, the internal area may be used for transporting cargo and tools, or used for other purposes. Longer loads, within legal regulations and with the mandatory safety flagging, may potentially be transported with the floor panel deployed. Conversion into a split tailgate differs according to the type of roof on the host vehicle.

To convert a folding extension into a split tailgate on a vehicle with an adjustable pop-top roof, initially refer to Figure 16. Remove the side door 61, side wall (obscured in the present figure), and vertical supports 58. Store elsewhere as the components are not part of the split tailgate configuration. Now refer to Figure 3. Remove bolts 35 and stoppers 34 from the track channels 33 in the cover panel 16. Refer to Figure 6. Slide the riding pins 40 out of the track channels 33 to separate the upper rear wall section 37 from the cover panel 16. Refer to Fig. 26. Allow the cover panel 16 to hang vertically. Fold the upper rear wall section 37 outwards and downwards to rest vertically beside the lower rear wall section 36. Remove the stairs 57 and store elsewhere. Remove bolts 35c, 35d, best illustrated in Figure 9, to detach the top sections 54a, 55a of the right-angled brackets from the bottom sections 54, 55. Separate the lower rear wall section 36 from the floor panel 13 and fully remove the co-joined upper and lower rear wall sections 37, 36, respectively (Figure 27), and store elsewhere. Refer to Figure 28. Use the grab rail 52 to swing the floor panel 13 up through approximately 90 degrees to the vertical position and secure closed by turning latch 28 in front of tab 29. Pull down vertically on handles 23 on the cover panel 16 to retract the pop-top roof 12. Preferably, the pop-top roof 12 remains lowered and secured when the invention is in split tailgate mode. Refer to Figure 25. Bolt 35e gas struts 80 to brackets 81 (one of each shown) on the cover panel 16 sides 32 and metal strips 18, or sides 69, 70 of the “U” shaped frame 67 shown in Figure 19. Referring to Figure 1, swing the cover panel 16 down to the vertical position and secure closed with the over-centre fasteners 17, 17a. When stowed, the external appearance of the split tailgate is similar to the folding extension/split tail gate 10 shown in Figures 1 and 2.

To convert a folding extension into a split tailgate on a vehicle with a fixed high-top roof initially refer to Figure 24. Remove the side door 61 and side wall (obscured in the present figure) and store elsewhere. Proceed as described in the immediately preceding aspect. However, if hinges have replaced track channels and riding pins, remove the hinge pins to separate the upper rear wall section from the cover panel. Disregard the step to pull down on the cover panel handles. The gas struts connect between the cover panel and sides 77, 78 of the rectangle shaped frame 74 shown in Figure 23. When stowed, the external appearance of the split tailgate of this embodiment is similar to the folding extension/split tailgate 10 shown in Figure 22.

2019101309 29 Oct 2019

The skilled addressee will now appreciate the advantages of the illustrated embodiments over the prior art. In one form the invention provides a device that can be fitted to multiple vehicle types with either a compatible adjustable pop-top or a fixed high-top roof including, but not limited to, utility-backed campers and canopies, 5 vans, troop carriers, convertible sports utilities, RV’s, 4x4’s, trucks, event trailers and caravans, or like vehicles. The folding extension/split tailgate apparatus may be a useful alternative to service canopies utilised by tradespeople. The invention is simple to use and in one embodiment is manually operated, however, larger versions of the invention may be fitted with mechanical or electric hydraulic lifting and lowering 10 assistance.

It is to be understood that the words “comprise” and “comprising” as used throughout the specification are to be interpreted in their inclusive form, i.e. use of the words “comprise” and “comprising” does not exclude the addition of other elements.

Various features of the invention have been particularly shown and described 15 in connection with the exemplified embodiments of the invention, however it must be understood that these particular arrangements merely illustrate the invention and it is not limited thereto. Accordingly, the invention can include various modifications, which fall within the spirit and scope of the invention.

Claims (7)

1. An expandable and convertible tailgate apparatus for a vehicle, comprising:

a cover panel hingedly connected to a roof of said vehicle or a frame attached thereto;

a floor panel hingedly connected to a floor of said vehicle or a frame attached thereto;

a lower rear wall section both fixedly and detachedly connected to said floor panel and generally perpendicular thereto;

an upper rear wall section hingedly connected to said lower wall section and slidably and/or pivotably engaging said cover panel, and wherein the expandable and convertible tailgate apparatus being movable between a retracted arrangement, whereby said lower and upper rear wall sections extend inwardly of an internal space of said vehicle and an expanded arrangement, wherein said cover panel and said floor panel extend outwardly from the vehicle, and said upper and lower rear wall sections are vertically coplanar, to thereby provide an extension to the internal space of said vehicle, or said upper and lower rear wall sections are removed to convert into a split tailgate configuration.

2. The apparatus in accordance with claim 1, wherein the roof of said vehicle is fixed, or the roof is reversibly adjustable upwardly to thereby form a pop-top configuration.

3. The apparatus in accordance with claim 1 or 2, wherein side wall portions are connectable between the vertically coplanar upper and lower rear wall sections, cover panel, floor panel and a rear edge, or side edge, of the vehicle, whereby the extension space is enclosable, and wherein at least some of said side wall portions include window/s, and/or screen/s, and/or door/s.

4. The apparatus in accordance with any one of the above claims, wherein as the floor panel is moved into a generally horizontal arrangement, the lower rear wall section that is fixedly connected thereto is drawn into a generally vertical arrangement, and the upper rear wall section, that is hingedly connected thereto is unfolded into a generally coplanar arrangement.

2019101309 29 Oct 2019

5. A method of expanding an internal space of a vehicle, including the steps of: providing an expandable and convertible tailgate apparatus for a vehicle, comprising a cover panel hingedly connectable to a roof of the vehicle or a frame attached thereto, a floor panel hingedly connectable to a floor of the

5 vehicle or a frame attached thereto, a lower rear wall section both fixedly and detachably connectable to the floor panel and generally perpendicular thereto, an upper rear wall section hingedly connectable to the lower rear wall section, and slidably and/or pivotably engageable with the cover panel; attaching the expandable and convertible tailgate apparatus to the vehicle;

10 moving the expandable and convertible tailgate apparatus from a folded retracted arrangement into an unfolded expanded arrangement, wherein the lower and upper rear wall sections extend inwardly of an internal space of the vehicle, and an expanded arrangement wherein the cover panel and floor panel extend outwardly from the vehicle, and upper and lower rear wall

15 sections are positioned in a generally vertical coplanar arrangement, to thereby provide an extension to the internal space of said vehicle, or said upper and lower rear wall sections are removed to convert into a split tailgate configuration.