Vehicle Back Panel Assembly With Integrated Rear Transverse Reinforcement
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Solution Overview
Problem
The existing back panel assembly for vehicles has low rigidity in the forward/rearward direction due to the separate bulkhead connection, leading to increased components, weight, and costs, and lacks direct reinforcement, affecting durability and noise, vibration, and harshness (NVH) performance.
Innovation Solution
A back panel assembly structure that integrates a rear transverse assembly member, rear transverse side reinforcement, and rear transverse extension member, eliminating the bulkhead and enhancing connectivity through welding and bonding, which improves rigidity and durability while reducing components and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a separate bulkhead is used to connect the back panel and reinforcement, then the components can be assembled separately, but the rigidity in the forward/rearward direction is low and the number of components increases
Solution Approach 1:
The bulkhead is integrated directly into the back panel structure, merging two previously separate components (back panel and bulkhead) into a single unified structure. This eliminates the need for separate bulkhead assembly while directly connecting the reinforcement to the back panel, thereby improving rigidity without compromising assembly ease.
2Ease of manufacture
If a separate bulkhead is used to connect the back panel and reinforcement, then the components can be manufactured independently, but the weight and costs increase
Solution Approach 1:
By integrating the bulkhead function directly into the back panel, the patent reduces the total number of components from three (back panel, bulkhead, reinforcement) to two (back panel with integrated bulkhead, reinforcement). This consolidation eliminates the weight of the separate bulkhead component and its associated fasteners, while still allowing the back panel and reinforcement to be manufactured independently and then assembled.
3Ease of operation
If the reinforcement is not directly connected to the rear transverse assembly member, then the assembly is easier, but the rigidity is low
Solution Approach 1:
The patent integrates the bulkhead connection directly into the back panel structure, creating a unified component that inherently connects the reinforcement to the rear transverse assembly member. This integrated design eliminates the need for separate bulkhead assembly steps while establishing direct structural connection, thereby improving rigidity without reducing assembly ease.
Data Source
AI summary
A back panel assembly forms a lower portion of a tailgate opening at a rear side of a vehicle and includes: a back panel extending from the lower portion of the tailgate opening at the rear side of the vehicle in a horizontal direction of a vehicle body and coupled to the vehicle body; a rear transverse assembly member disposed in the horizontal direction of the vehicle body and coupled to cover a center portion of the back panel; a rear transverse side reinforcement coupled to a lateral portion of the rear transverse assembly member and extending to the outside of the vehicle; and a rear transverse extension member coupled to an upper portion of the rear transverse side reinforcement.