A rear door structure for a crossover vehicle and a manufacturing method thereof

Abstract

This invention discloses a tailgate structure for crossover vehicles and its manufacturing method. It employs a pre-divided sheet metal outer panel and inner panel, which are then joined and molded together to form a tailgate structure made of sheet metal, reducing production and subsequent maintenance costs. The outer sheet metal panel is divided into an outer upper panel, an outer middle panel, and an outer lower panel according to pre-set parameters. The inner sheet metal panel is divided into an inner main panel and an inner frame according to pre-set parameters. Each component meets the styling requirements of its respective area. They are then assembled together using methods such as gluing, edge banding, and welding to form a streamlined, steeply angled, and large-sized sheet metal tailgate. The price of sheet metal is lower than that of resin, reducing production costs. In the event of a rear-end collision, only partial repairs of the sheet metal are needed, eliminating the need to replace the entire tailgate, further reducing subsequent maintenance costs.

Description

Technical Field

[0001] This invention relates to the field of vehicle tailgate technology, and more particularly to a tailgate structure for crossover vehicles and its manufacturing method. Background Technology

[0002] Crossover-style vehicles are increasingly common in the market. These vehicles, while adopting the styling of a sedan, offer the trunk space of a hatchback, making them popular with many users. Crossovers typically feature a steeply sloping and elongated tailgate to create a streamlined silhouette, resulting in a more impactful appearance. Many crossover models are currently available, such as the BMW X3, X4, X6, Honda Crosstour, Lynk & Co 05, and Haval F7x. These crossovers all feature a sloping rear end, contributing to a streamlined rear profile. Compared to traditional vehicles, crossovers require a more forward-positioned tailgate with a steeper slope and smoother curves to achieve their streamlined design.

[0003] Existing one-piece sheet metal tailgates cannot accommodate the tailgate designs of crossover vehicles with steep angles and long dimensions. Therefore, current technologies often use resin to achieve the tailgate design for crossovers. However, using resin to manufacture the tailgate of crossover vehicles leads to higher production costs, increasing the cost of the tailgate by approximately RMB 1500 per unit. In the event of a rear-end collision, the entire tailgate needs to be replaced, resulting in high repair costs. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and provide a tailgate structure for crossover vehicles and its manufacturing method. The tailgate structure is made of sheet metal by pre-dividing the outer sheet metal panel and the inner sheet metal panel and then connecting them in the later stage, thereby reducing production costs and later maintenance costs.

[0005] The present invention provides a tailgate structure for a crossover vehicle, comprising an outer sheet metal panel and an inner sheet metal panel connected to the outer sheet metal panel;

[0006] The sheet metal outer panel includes a split outer upper plate, an outer middle plate, and an outer lower plate. The outer upper plate is U-shaped, and the outer upper plate and the outer middle plate form an outer panel mounting window for installing glass. The rear side of the outer middle plate is provided with a taillight mounting groove.

[0007] The sheet metal inner panel includes an inner panel frame and an inner panel main board connected to the lower middle part of the inner panel frame. An inner panel mounting window for installing glass is formed between the top of the inner panel main board and the inner panel frame. The inner side of the inner panel frame has a sealing surface. A door lock bracket is installed on the inner side of the lower frame of the inner panel frame.

[0008] The distance between the left and right edges of the inner main board and the sealing surfaces on both sides is greater than a preset distance, and the lower edge of the inner main board is above the door lock bracket.

[0009] In one of the alternative technical solutions, the outer plate includes a tail wing and a taillight mounting plate that are connected separately;

[0010] The tail fin includes an upper extension plate that extends backward and downward, a rear end plate that is connected to the upper extension plate and extends downward, and a lower extension plate that is connected to the rear end plate and extends forward and downward. The lower end of the lower extension plate has a downward extending extension plate flange, and the middle of the extension plate flange is provided with a taillight main positioning hole.

[0011] The taillight mounting slot is located on the upper part of the taillight mounting plate, and the upper edge of the taillight mounting slot is connected to the flange of the extension plate.

[0012] In one of the alternative technical solutions, the inner motherboard includes a motherboard body and a motherboard crossbeam connected to the top of the motherboard body, and the motherboard crossbeam is welded to the outer middle plate.

[0013] In one of the optional technical solutions, the preset distance is greater than or equal to 100mm.

[0014] In one of the alternative technical solutions, the lower frame is provided with an upwardly extending lower frame extension plate, and the door lock bracket is installed on the inner side of the lower frame extension plate;

[0015] The door lock bracket includes two bracket side plates and a bracket base plate connected between the lower ends of the two bracket side plates. The bracket side plates and the bracket base plate are respectively connected to the lower frame extension plate, and the bracket base plate is also connected to the lower frame.

[0016] The bracket base plate has a bottom plate through hole for the lock head of the door lock to pass through.

[0017] In one of the alternative technical solutions, the inner main plate has a U-shaped or trapezoidal reinforcing boss on the side facing the outer lower plate, and the opening of the reinforcing boss gradually increases in the direction from bottom to top;

[0018] The reinforcing boss is connected to the lower plate of the outer panel.

[0019] In one of the alternative technical solutions, the inner main board is provided with three reinforcing brackets arranged in a triangle on the side facing the outer lower board. The reinforcing brackets are located inside the reinforcing boss and are connected to the outer lower board.

[0020] In one of the alternative technical solutions, an X-direction fixing bracket is installed in the middle of the side frame of the inner panel frame, and a gap adjustment component is installed on the X-direction fixing bracket.

[0021] In one of the alternative technical solutions, an anti-pinch strip is installed on the outer side of the sealing surface of the inner panel frame. The anti-pinch strip is connected to the taillight housing by a buckle, and the side of the anti-pinch strip extends with an anti-pinch strip flange for covering the end of the taillight.

[0022] The present invention also provides a method for manufacturing a tailgate structure for a crossover vehicle, comprising the following steps:

[0023] Based on the preset parameters of the parts, the outer plate upper plate, outer plate middle plate, outer plate lower plate, inner plate frame and inner plate main plate are pre-manufactured;

[0024] The outer panel upper plate, outer panel middle plate and outer panel lower plate are connected to form a sheet metal outer panel, and the inner panel main plate and inner panel frame are connected to form a sheet metal inner panel.

[0025] The inner sheet metal panel is connected to the outer sheet metal panel to form the tailgate structure for crossover vehicles.

[0026] The above technical solution has the following beneficial effects:

[0027] The present invention provides a tailgate structure for crossover vehicles and a method for manufacturing the same, which adopts a method of pre-dividing sheet metal outer panels and sheet metal inner panels and then connecting and forming them to form a tailgate structure made of sheet metal, thereby reducing production costs and subsequent maintenance costs.

[0028] Specifically, the outer sheet metal panel is divided into the outer upper plate, the middle outer plate, and the lower outer plate according to the preset parameters. The inner sheet metal panel is divided into the inner main plate and the inner frame according to the preset parameters. Each component meets the styling requirements of each part. Later, they are assembled together by means of gluing, edge wrapping, welding, etc., to form a streamlined, steeply angled, and large-sized sheet metal rear door.

[0029] The price of sheet metal is lower than that of resin, reducing production costs. In the event of a rear-end collision, only partial sheet metal repairs are needed, eliminating the need to replace the entire tailgate, thus reducing future maintenance costs. Attached Figure Description

[0030] The disclosure of this invention will become more readily understood by referring to the accompanying drawings. It should be understood that these drawings are for illustrative purposes only and are not intended to limit the scope of protection of this invention. In the drawings:

[0031] Figure 1 This is a perspective view of a rear tailgate structure provided in an embodiment of the present invention;

[0032] Figure 2 for Figure 1 The side view of the rear tailgate structure shown;

[0033] Figure 3 This is a 3D view of the sheet metal outer panel;

[0034] Figure 4 This is a rear view of the sheet metal outer panel;

[0035] Figure 5 This is an exploded view of the sheet metal outer panel;

[0036] Figure 6 A three-dimensional view of the outer panel;

[0037] Figure 7 This is the rear view of the outer panel and the middle panel;

[0038] Figure 8 for Figure 3 Cross-sectional view along direction AA;

[0039] Figure 9 This is a cross-sectional view of the outer and middle plates;

[0040] Figure 10 This is a three-dimensional view of the tail fin plate of the outer and middle plates;

[0041] Figure 11 A 3D view of the taillight mounting plate on the outer and middle panels;

[0042] Figure 12 This is a side view of the inner sheet metal panel;

[0043] Figure 13 This is a 3D view of the sheet metal inner panel;

[0044] Figure 14 This is a front view of the sheet metal inner panel;

[0045] Figure 15 A 3D view showing the connection between the motherboard body and the inner board frame of the inner board.

[0046] Figure 16 This is a schematic diagram of the motherboard's crossbeam.

[0047] Figure 17 A 3D view showing the door lock bracket connected to the lower part of the inner panel frame;

[0048] Figure 18 A 3D view of the door lock bracket;

[0049] Figure 19 A schematic diagram showing that the rear surface of the inner motherboard has a U-shaped or trapezoidal reinforcing boss and three reinforcing brackets;

[0050] Figure 20 This is a schematic diagram showing that one side of the inner panel frame is equipped with an electric support rod and an anti-pinch strip;

[0051] Figure 21 for Figure 20 Enlarged view of region B;

[0052] Figure 22 for Figure 21 A sectional view along the CC direction;

[0053] Figure 23 A schematic diagram showing the X-axis fixed bracket installed on the side frame;

[0054] Figure 24 A schematic diagram showing the anti-squeezing strip installed on the side frame;

[0055] Figure 25 This is a 3D view of one end of the taillight;

[0056] Figure 26 A diagram illustrating how the taillight tip can be prevented from being obscured by the folded-over trim.

[0057] Figure 27 This is a diagram illustrating the assembly of the taillight and the protective strip. Detailed Implementation

[0058] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings. Identical components are indicated by the same reference numerals. It should be noted that the terms "front," "rear," "left," "right," "up," and "down" used in the following description refer to directions in the accompanying drawings, while the terms "inner" and "outer" refer to directions toward or away from the geometric center of a specific component, respectively.

[0059] like Figure 1-7 and Figure 12-16 As shown, an embodiment of the present invention provides a tailgate structure for a crossover vehicle, including an outer sheet metal panel 1 and an inner sheet metal panel 2 connected to the outer sheet metal panel 1.

[0060] The sheet metal outer panel 1 includes a separate upper outer panel 11, a middle outer panel 12, and a lower outer panel 13. The upper outer panel 11 is U-shaped, and the upper outer panel 11 and the middle outer panel 12 form an outer panel mounting window 14 for installing glass. The rear side of the middle outer panel 12 is provided with a taillight mounting groove 120.

[0061] The sheet metal inner panel 2 includes an inner panel frame 21 and an inner panel main board 22 connected to the lower middle part of the inner panel frame 21. An inner panel mounting window 23 for installing glass is formed between the top of the inner panel main board 22 and the inner panel frame 21. The inner side of the inner panel frame 21 has a sealing surface 214. A door lock bracket 3 is installed on the inner side of the lower frame 211 of the inner panel frame 21.

[0062] The distance between the left and right edges of the inner main board 22 and the sealing surfaces 214 on both sides is greater than the preset distance, and the lower edge of the inner main board 22 is above the door lock bracket 3.

[0063] The tailgate structure provided by this invention is mainly used in crossover vehicles. Both the inner and outer panels of this tailgate structure are made of sheet metal. The outer sheet metal panel 1 and the inner sheet metal panel 2 are formed by connecting pre-fabricated sheet metal, frames, and other components, rather than using the traditional one-piece molding process. This allows for pre-adjustment of component parameters according to vehicle model requirements, to meet the streamlined or fastback design of the crossover tailgate. These parameters include, but are not limited to, dimensions, position, strength, slope, and curvature.

[0064] Using computer-generated data, the sheet metal outer panel 1 can be pre-divided into an outer upper plate 11, an outer middle plate 12, and an outer lower plate 13 according to predetermined positions. Then, these plates are manufactured using processes such as stamping and forging. Finally, they are sequentially connected to form the sheet metal outer panel 1. Similarly, the sheet metal inner panel 2 can be pre-divided into an inner panel frame 21 and an inner panel main plate 22 according to predetermined positions. These frames are then manufactured using processes such as stamping and forging. Finally, they are connected to form the sheet metal inner panel 2. The sheet metal inner panel 2 is then connected to the sheet metal outer panel 1 to form the rear door structure. The connection methods between the sheet metal parts in this invention include, but are not limited to, welding, gluing, riveting, and edge pressing.

[0065] Of course, the outer plate 11, outer middle plate 12, outer lower plate 13, inner frame 21 and inner main plate 22 can also be pre-divided into sub-components as needed and assembled in a similar manner.

[0066] Specifically, the sheet metal outer panel 1 is composed of an outer upper plate 11, an outer middle plate 12, and an outer lower plate 13 connected sequentially. It is constructed using a separate connection method rather than a one-piece molding method. The outer upper plate 11 is U-shaped, with both ends connected to the outer middle plate 12, forming an outer panel mounting window 14 for installing glass. That is, the lower edge of the outer upper plate 11 roughly reaches the lower boundary of the outer panel mounting window 14, and the upper edge of the outer middle plate 12 also roughly reaches the lower boundary of the outer panel mounting window 14. The panel is segmented along the lower edge of the shaped glass to ensure the welding, precision, and quality performance of the parts, and to improve the material utilization rate of the sheet metal.

[0067] The glass mounting positioning hole 112 is on the outer plate 11 to improve the glass positioning accuracy.

[0068] The outer middle plate 12 has a taillight mounting slot 120 on its rear side for mounting taillights 9. The taillight mounting slot 120 extends through the outer middle plate 12 in the horizontal or Y direction, allowing for the mounting of a through-type taillight. The outer lower plate 13 is connected to the lower part of the outer middle plate 12 and is essentially a rear end cover.

[0069] Along the front-to-back direction, the slope of the outer panel 11 is less than the slope of the middle outer panel 12, which is less than the slope of the lower outer panel 13. The middle outer panel 12 can be made with concave and convex structures, such as a rear spoiler, according to the vehicle model requirements. The slope of each panel is the inclination of the line connecting the lower end to the upper end of the panel. By adjusting the slope of each panel, the streamlined shape or fastback shape of the crossover's tailgate can be achieved.

[0070] The sheet metal inner panel 2 is partially divided in the lower area of ​​the inner panel glass to facilitate separate forming and connection. The door lock installation structure is changed from the traditional installation between the inner and outer panels to installation on the inner side of the inner panel, so as to facilitate the overall forming of the inner panel frame 21. The installation of the door lock 4 is more flexible, the requirements for the type of door lock 4 are lower, there are more candidate suppliers, and more choices are available.

[0071] Specifically, the sheet metal inner panel 2 is formed by connecting the inner panel frame 21 and the inner panel main panel 22. The inner panel frame 21 is the frame structure of the sheet metal inner panel 2 and can be integrally formed. The inner panel frame 21 includes a lower frame 211, an upper frame 213, and side frames 212 on both sides. Sealing surfaces 214 are formed on the inner surfaces (surfaces opposite to the outer panel side) of the lower frame 211, side frames 212, and upper frame 213 for sealing with the sealing surface of the vehicle body when closed. The door lock bracket 3 is installed on the inner side of the lower frame 211 for installing the door lock 4.

[0072] The inner panel main board 22 is connected to the lower middle part of the inner panel frame 21, which enhances the rigidity of the sheet metal inner panel 2. An inner panel mounting window 23 is formed between the top of the inner panel main board 22 and the inner panel frame 21, which is aligned with the boundary of the outer panel mounting window 14 for mounting decorative glass.

[0073] The inner panel main board 22 is roughly rectangular in shape. The upper boundary of the inner panel main board 22 extends to the lower edge of the inner panel mounting window 23, and the lower boundary of the inner panel main board 22 extends to the top of the door lock bracket 3 of the inner panel mounting window 23. The left and right boundaries of the inner panel main board 22 are a distance away from the sealing surfaces 214 on both sides to avoid affecting the flatness of the sealing surfaces 214.

[0074] In summary, the rear door structure for crossover vehicles provided by the present invention is made of sheet metal by pre-dividing the outer sheet metal panel 1 and the inner sheet metal panel 2 and then connecting them in the later stage, thereby reducing production costs and subsequent maintenance costs.

[0075] The price of sheet metal is lower than that of resin, reducing production costs. In the event of a rear-end collision, only partial sheet metal repairs are needed, eliminating the need to replace the entire tailgate, thus reducing future maintenance costs.

[0076] In one embodiment, such as Figure 7-11 As shown, the outer panel 12 includes a tail wing 122 and a taillight mounting plate 123 that are connected separately.

[0077] The rear wing 122 includes an upper extension plate 1221 that extends backward and downward, a rear end plate 1222 that is connected to the upper extension plate 1221 and extends downward, and a lower extension plate 1223 that is connected to the rear end plate 1222 and extends forward and downward. The lower end of the lower extension plate 1223 has a downward extending extension plate flange 1224, and the middle of the extension plate flange 1224 is provided with a taillight main positioning hole 1225.

[0078] The taillight mounting slot 120 is located on the upper part of the taillight mounting plate 123, and the upper edge of the taillight mounting slot 120 is connected to the extension plate flange 1224.

[0079] In this embodiment, the outer middle plate 12 is divided into a rear wing 122 and a taillight mounting plate 123. The rear wing 122 is connected to the front middle plate main plate 121, and the two can be integrally formed.

[0080] The top edges of the middle plate main board 121 are connected to both ends of the outer plate main board 11. The edging 111 at both ends of the outer plate main board 11 covers the middle plate main board 121 and is soldered.

[0081] The rear wing 122 features tail wing characteristics and serves as a spoiler. The rear wing 122 includes an integrally formed upper extension plate 1221, a rear end plate 1222, a lower extension plate 1223, and an extension plate flange 1224. The rear end of the middle plate main plate 121 connects to the front end of the upper extension plate 1221. The slope of the middle plate main plate 121 is greater than that of the upper extension plate 1221. The rear end plate 1222 extends downwards from the rear end of the upper extension plate 1221. The lower extension plate 1223 extends forward and downwards from the lower end of the rear end plate 1222. The extension plate flange 1224 extends downwards from the lower end of the lower extension plate 1223. The taillight main positioning hole 1225 is located in the middle of the extension plate flange 1224.

[0082] The taillight mounting slot 120 is located on the upper part of the taillight mounting plate 123. The upper edge 1231 of the taillight mounting plate 123 (which is also the base plate of the taillight mounting slot 120) is connected to the flange 1224 of the extension plate, and a positioning groove 1232 is formed in the middle of the upper edge 1231 corresponding to the position of the taillight main positioning hole 1225. When installing the taillight, bolts or screws pass through the taillight main positioning hole 1225 and the positioning groove 1232 to position the taillight.

[0083] In this embodiment, during the segmentation, the taillight mounting slot 120 is left on the taillight mounting plate 123, and the taillight main positioning hole 1225 is set on the rear wing plate 122. This ensures that the structure of the taillight mounting slot 120 is completed so that the through taillight can be installed. The taillight is also positioned by the taillight main positioning hole 1225 and the positioning groove 1232, which ensures the installation accuracy of the taillight.

[0084] The dividing part should be placed at the top of the taillight mounting plate 123 as much as possible (only enough space is reserved for welding) to ensure the formability of the tail wing 122.

[0085] The taillight mounting plate 123 integrates the taillight mounting base in a segmented manner, which helps to save costs.

[0086] The taillight mounting plate 123 is also provided with a license plate 1233 below the taillight mounting slot 120, which is used to install the license plate, license plate light, tailgate switch, etc.

[0087] In one embodiment, such as Figure 13-16 As shown, the inner motherboard 22 includes a motherboard body 221 and a motherboard crossbeam 222 connected to the top of the motherboard body 221. The motherboard crossbeam 222 is welded to the outer middle board 12.

[0088] In this embodiment, to facilitate the connection between the inner main board 22 and the inner frame 21 and the sheet metal outer board 1, the inner main board 22 is divided into a main board body 221 and a main board crossbeam 222, with the crossbeam 222 connected to the top of the main board body 221. During assembly, the main board body 221 and the inner frame 21 are first overlapped and welded. The inner sides of the lower frame 211 and the side frame 212 both have extension plates for welding connections. Figure 15 The inner panel frame 21 has a notch 215 on the lower side of the inner panel mounting window 23. The main board crossbeam 222 is installed in the notch 215. It is first welded to the main board body 221 and the side frame 212. During the inner and outer assembly, the main board crossbeam 222 is welded to the outer panel middle plate 12 to improve the structural strength.

[0089] In one embodiment, the preset distance is greater than or equal to 100mm, that is, the boundaries of the left and right sides of the inner board 22 are more than 100mm away from the sealing surfaces 214 on both sides, so as to ensure that the sealing surfaces 214 are not affected.

[0090] In one embodiment, such as Figure 12 and Figure 17-18 As shown, the lower frame 211 is provided with an upwardly extending lower frame extension plate 216, and the door lock bracket 3 is installed on the inner side of the lower frame extension plate 216.

[0091] The door lock bracket 3 includes two bracket side plates 32 and a bracket base plate 31 connected between the lower ends of the two bracket side plates 32. The bracket side plates 32 and the bracket base plate 31 are respectively connected to the lower frame extension plate 216, and the bracket base plate 31 is also connected to the lower frame 211.

[0092] The bracket base plate 31 is provided with a base plate through hole 311 for the lock head 41 of the door lock 4 to pass through.

[0093] In this embodiment, the door lock bracket 3 is U-shaped and includes two bracket side plates 32 and a bracket base plate 31 connected between the lower ends of the two bracket side plates 32.

[0094] The lower frame 211 has an upwardly extending lower frame extension plate 216 in the middle position. The bracket side plate 32 and the bracket base plate 31 are respectively provided with welding flanges. The bracket side plate 32 and the bracket base plate 31 are respectively welded to the lower frame extension plate 216. The bracket base plate 31 is also welded to the lower frame 211 to firmly install the door lock bracket 3 on one side of the lower frame 211.

[0095] The lower frame extension plate 216 has an opening 2161 located between the two bracket side plates 32. It can be used to install parts connected to the door lock 4, and also serves to reduce weight.

[0096] The bracket base plate 31 is provided with a base plate through hole 311 for the lock head 41 of the door lock 4 to pass through downward.

[0097] In one embodiment, such as Figure 19 As shown, the inner main plate 22 has a U-shaped or trapezoidal reinforcing boss 223 on the side facing the outer lower plate 13. The opening of the U-shaped or trapezoidal reinforcing boss 223 gradually increases in size along the upward direction. The reinforcing boss 223 is connected to the outer lower plate 13.

[0098] In this embodiment, a reinforcing boss 223 is provided on the outer side of the inner main board 22 (the side of the inner main board 22 facing the outer lower board 13). The overall shape of the reinforcing boss 223 is U-shaped or trapezoidal, and the opening of the reinforcing boss 223 gradually increases in the direction from bottom to top. The reinforcing boss 223 is connected to the outer lower board 13 by adhesive to improve the rigidity of the connection area.

[0099] The reinforced boss 223 is located around the door lock bracket 3 and adopts a U-shaped or trapezoidal closed-loop structure, which helps to improve the structural strength and NVH performance of the door lock installation location.

[0100] In one embodiment, such as Figure 19 As shown, the inner main plate 22 has three reinforcing brackets 224 arranged in a triangle on the side facing the outer lower plate 13. The reinforcing brackets 224 are located inside the U-shaped or trapezoidal reinforcing bosses 223 and are connected to the outer lower plate 13.

[0101] In this embodiment, three reinforcing brackets 224 are provided on the outer side of the inner main plate 22 (the side of the inner main plate 22 facing the outer lower plate 13). The three reinforcing brackets 224 are all located inside the U-shaped or trapezoidal reinforcing boss 223. The three reinforcing brackets 224 are arranged in a triangle. The two upper reinforcing brackets 224 are located at the opening of the U-shaped or trapezoidal reinforcing boss 223, and the lower reinforcing bracket 224 is located in the middle area of ​​the U-shaped or trapezoidal reinforcing boss 223. The three reinforcing brackets 224 are respectively connected to the outer lower plate 13 by adhesive, which further improves the structural rigidity.

[0102] In one embodiment, such as Figure 20-23 As shown, an X-direction fixing bracket 6 is installed in the middle of the side frame 212 of the inner panel frame 21, and a gap adjustment component 7 is installed on the X-direction fixing bracket 6.

[0103] In this embodiment, the gap adjustment member 7 (RUB) and the bracket of the gas spring 5 are installed in the middle area of ​​the side frame 212, making it easier to adjust the gap difference of the sensitive middle part of the back door.

[0104] Specifically, an X-direction fixing bracket 6 is installed in the middle area along the vertical direction of the side frame 212. The X-direction fixing bracket 6 extends along the front-to-back direction (X-direction) when the tailgate is closed. A gap adjustment member 7 is used to adjust the surface difference between the sealing surface 214 of the side frame 212 and the sealing surface of the vehicle body. The axial direction of the gap adjustment member 7 is the same as the extension direction of the X-direction fixing bracket 6. The force direction of the gap adjustment member 7 is perpendicular to the mounting surface of the X-direction fixing bracket 6 and is not tilted, resulting in uniform force distribution. This ensures that the X-direction fixing bracket 6 is not easily deformed and is durable.

[0105] In one embodiment, such as Figure 24-27 As shown, an anti-pinch strip 8 is installed on the outer side of the sealing surface 214 of the inner panel frame 21. The anti-pinch strip 8 is connected to the housing of the taillight 9 through a buckle 10. The side of the anti-pinch strip 8 extends with an anti-pinch strip flange 81 for covering the end of the taillight 9.

[0106] In this embodiment, the taillight 9 installed in the taillight mounting slot 120 is a through-type taillight, and connecting portions 91 are provided at both ends of the taillight 9 housing. The connecting portions 91 can be injection-molded holes. The anti-pinch strip 8 is installed on the side of the inner panel frame 21 facing away from the outer panel, and the anti-pinch strip 8 is located on the outer side of the sealing surface 214 on the inner panel frame 21 (the outer side here refers to the side facing the edge of the inner panel frame 21), which plays a role in anti-pinch protection. The anti-pinch strip 8 is also fixed to the housing of the taillight 9 by a buckle 10 near the end, and the buckle 10 is connected to the connecting portion 91. The side of the anti-pinch strip 8 extends with an anti-pinch strip flange 81, which is used to cover the end of the taillight 9. Specifically, the end of the taillight 9 has a notch 92, and the anti-pinch strip flange 81 extends into the notch 92. The anti-pinch strip flange 81 can be painted the same color as the surrounding parts, which replaces the traditional method of covering the notch 92 by the taillight base, saving costs.

[0107] An embodiment of the present invention provides a method for manufacturing a tailgate structure for a crossover vehicle, comprising the following steps:

[0108] Based on the preset parameters of the parts, the outer plate upper plate 11, the outer plate middle plate 12, the outer plate lower plate 13, the inner plate frame 21, and the inner plate main plate 22 are pre-manufactured.

[0109] The outer panel upper plate 11, the outer panel middle plate 12 and the outer panel lower plate 13 are connected to form the sheet metal outer panel 1, and the inner panel main plate 22 and the inner panel frame 21 are connected to form the sheet metal inner panel 2.

[0110] The inner sheet metal panel 2 and the outer sheet metal panel 1 are connected to form a tailgate structure for crossover vehicles.

[0111] This invention provides a manufacturing method for a rear hatch structure of a crossover vehicle. Using computer-generated data, a sheet metal outer panel 1 is pre-divided into an outer upper plate 11, an outer middle plate 12, and an outer lower plate 13 according to predetermined positions. These plates are then manufactured using processes such as stamping and forging. Finally, the outer upper plate 11, outer middle plate 12, and outer lower plate 13 are sequentially connected together to form the sheet metal outer panel 1. Similarly, a sheet metal inner panel 2 is pre-divided into an inner panel frame 21 and an inner panel main plate 22 according to predetermined positions. These frames are then manufactured using processes such as stamping and forging. Finally, the inner panel frame 21 and inner panel main plate 22 are connected together to form the sheet metal inner panel 2. The sheet metal inner panel 2 is then connected to the sheet metal outer panel 1 to form the rear hatch structure. The connection methods between the sheet metal parts in this invention include, but are not limited to, welding, gluing, riveting, and edge pressing.

[0112] Of course, the outer plate 11, outer middle plate 12, outer lower plate 13, inner frame 21 and inner main plate 22 can also be pre-divided into sub-components as needed and assembled in a similar manner.

[0113] The present invention provides a method for manufacturing a tailgate structure for crossover vehicles, which adopts a method of pre-dividing sheet metal outer panels and sheet metal inner panels and then connecting and forming them to form a tailgate structure made of sheet metal, thereby reducing production costs and subsequent maintenance costs.

[0114] The price of sheet metal is lower than that of resin, reducing production costs. In the event of a rear-end collision, only partial sheet metal repairs are needed, eliminating the need to replace the entire tailgate, thus reducing future maintenance costs.

[0115] As needed, the above technical solutions can be combined to achieve the best technical effect.

[0116] The above are merely the principles and preferred embodiments of the present invention. It should be noted that, for those skilled in the art, several other modifications can be made based on the principles of the present invention, and these modifications should also be considered within the scope of protection of the present invention.

Claims

1. A tailgate structure for a crossover vehicle, characterized in that, It includes a sheet metal outer panel (1) and a sheet metal inner panel (2) connected to the sheet metal outer panel (1); The sheet metal outer panel (1) includes a split-connected outer upper plate (11), an outer middle plate (12), and an outer lower plate (13). The outer upper plate (11) is U-shaped. The outer upper plate (11) and the outer middle plate (12) form an outer panel mounting window (14) for installing glass. The rear side of the outer middle plate (12) is provided with a taillight mounting groove (120). Along the front-to-back direction, the slope of the upper plate (11) of the outer plate is less than the slope of the middle plate (12) of the outer plate and less than the slope of the lower plate (13) of the outer plate. By adjusting the slope of each plate, the streamlined fastback shape of the rear door of the crossover vehicle is satisfied. The outer plate (12) includes a main plate (121), a tail wing (122) and a taillight mounting plate (123). The top edges of the main plate (121) are connected to both ends of the outer plate (11). The edging (111) at both ends of the outer plate (11) wraps around the main plate (121) and is welded. The sheet metal inner panel (2) includes an inner panel frame (21) and an inner panel main board (22) connected to the lower middle part of the inner panel frame (21). An inner panel mounting window (23) for installing glass is formed between the top of the inner panel main board (22) and the inner panel frame (21). The inner side of the inner panel frame (21) has a sealing surface (214). A door lock bracket (3) is installed on the inner side of the lower frame (211) of the inner panel frame (21). The distance between the left and right edges of the inner main board (22) and the sealing surfaces (214) on both sides is greater than a preset distance to avoid affecting the flatness of the sealing surfaces (214); the lower edge of the inner main board (22) is above the door lock bracket (3); The inner panel main board (22) includes a main board body (221) and a main board crossbeam (222) connected to the top of the main board body (221). The inner panel frame (21) has a notch (215) on the lower side of the inner panel mounting window (23). The main board crossbeam (222) is installed in the notch (215). The main board crossbeam (222) is first welded to the main board body (221) and the side frame (212). During the inner and outer assembly, the main board crossbeam (222) is welded to the outer panel middle plate (12). The sheet metal inner panel (2) is partially divided in the lower part of the inner panel glass so that it can be connected in separate parts. The door lock mounting structure is installed on the inner side of the sheet metal inner panel (2) so that the inner panel frame (21) can be formed as a whole.

2. The tailgate structure for a crossover vehicle according to claim 1, characterized in that, The tail wing (122) includes an upper extension plate (1221) that extends backward and downward, a rear end plate (1222) that is connected to the upper extension plate (1221) and extends downward, and a lower extension plate (1223) that is connected to the rear end plate (1222) and extends forward and downward. The lower end of the lower extension plate (1223) has a downward extending extension plate flange (1224), and the middle of the extension plate flange (1224) is provided with a taillight main positioning hole (1225). The taillight mounting slot (120) is located on the upper part of the taillight mounting plate (123), and the upper edge of the taillight mounting slot (120) is connected to the flange (1224) of the extension plate.

3. The tailgate structure for a crossover vehicle according to claim 1, characterized in that, The preset distance is greater than or equal to 100mm.

4. The tailgate structure for a crossover vehicle according to claim 1, characterized in that, The lower frame (211) is provided with an upwardly extending lower frame extension plate (216), and the door lock bracket (3) is installed on the inner side of the lower frame extension plate (216); The door lock bracket (3) includes two bracket side plates (32) and a bracket base plate (31) connected between the lower ends of the two bracket side plates (32). The bracket side plates (32) and the bracket base plate (31) are respectively connected to the lower frame extension plate (216), and the bracket base plate (31) is also connected to the lower frame (211). The bracket base plate (31) is provided with a base plate through hole (311) through which the lock head (41) of the door lock (4) passes.

5. The tailgate structure for a crossover vehicle according to claim 1, characterized in that, The inner main plate (22) has a U-shaped or trapezoidal reinforcing boss (223) on the side facing the outer lower plate (13), and the opening of the reinforcing boss (223) gradually increases along the direction from bottom to top; The reinforcing boss (223) is connected to the lower plate of the outer plate (13).

6. The tailgate structure for a crossover vehicle according to claim 5, characterized in that, The inner main plate (22) has three reinforcing brackets (224) arranged in a triangle on the side facing the outer lower plate (13). The reinforcing brackets (224) are located inside the reinforcing boss (223) and are connected to the outer lower plate (13).

7. The tailgate structure for a crossover vehicle according to claim 1, characterized in that, An X-direction fixing bracket (6) is installed in the middle of the side frame (212) of the inner plate frame (21), and a gap adjustment component (7) is installed on the X-direction fixing bracket (6).

8. The tailgate structure for a crossover vehicle according to claim 1, characterized in that, An anti-pinch strip (8) is installed on the outer side of the sealing surface (214) of the inner panel frame (21). The anti-pinch strip (8) is connected to the housing of the taillight (9) by a buckle (10). The side of the anti-pinch strip (8) extends with an anti-pinch strip flange (81) for blocking the end of the taillight (9).

9. A method for manufacturing a tailgate structure for a crossover vehicle as described in any one of claims 1-8, characterized in that, Includes the following steps: According to the preset parameters of the parts, the outer plate upper plate (11), the outer plate middle plate (12), the outer plate lower plate (13), the inner plate frame (21), and the inner plate main plate (22) are pre-manufactured. The outer plate upper plate (11), the outer plate middle plate (12) and the outer plate lower plate (13) are connected to form a sheet metal outer plate (1), and the inner plate main plate (22) and the inner plate frame (21) are connected to form a sheet metal inner plate (2). The inner sheet metal panel (2) is connected to the outer sheet metal panel (1) to form a rear tailgate structure for crossover vehicles.

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