Hybrid Composite Tailgate With Continuous Load Path Reinforcement
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Solution Overview
Problem
Current automotive tailgates face challenges in weight reduction and cost efficiency due to the use of heavy metals like aluminum, which are costly and require additional components for aesthetic and mechanical purposes.
Innovation Solution
A hybrid tailgate design featuring a thermoplastic inner structure with composite reinforcement parts, specifically continuous fiber reinforced inserts, that form a continuous load path to reinforce the carrier frame and enclose the tailgate window opening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If aluminum is used for tailgate inner structure, then mechanical properties are maintained, but weight increases and costs increase
Solution Approach 1:
The patent applies composite materials by combining thermoplastic polyolefin (TPO) matrix with long glass fiber (LGF) reinforcement to create a lightweight inner structure that maintains mechanical properties. The composite material PP-LGF provides both structural strength and weight reduction, replacing traditional aluminum while meeting mechanical requirements through the synergistic combination of polymer matrix and fiber reinforcement.
Solution Approach 2:
The patent changes material parameters by transitioning from metallic aluminum to polymeric composite PP-LGF, altering density, strength-to-weight ratio, and thermal properties. This parameter change enables weight reduction while maintaining structural integrity through optimized fiber orientation, length, and distribution within the thermoplastic matrix.
2Strength
If aluminum is used for tailgate inner structure, then mechanical properties are maintained, but costs increase due to material and cladding requirements
Solution Approach 1:
The use of composite material PP-LGF eliminates the need for separate cladding operations required with aluminum, as the composite itself provides both structural and aesthetic functions. This integration reduces manufacturing steps, labor costs, and material waste associated with cladding processes.
Solution Approach 2:
The patent merges the structural inner structure and aesthetic cladding into a single integrated composite component. The TPO matrix with LGF reinforcement simultaneously provides mechanical strength and surface quality, eliminating the need for separate aluminum substrate and cladding layers, thereby reducing overall manufacturing complexity and cost.
3Reliability
If metal inserts are used in plastic tailgate, then mechanical and thermal expansion requirements are met, but weight reduction is limited and costs increase
Solution Approach 1:
The patent replaces permanent metal inserts with thermoplastic-based solutions that can be integrated directly into the molded part. The thermoplastic material provides sufficient mechanical attachment and thermal expansion compatibility without requiring separate metal components, achieving weight reduction while maintaining functional reliability through material compatibility and integrated design.
4Weight of moving object
If continuous fiber reinforced inserts replace metal inserts, then weight is reduced and costs are reduced, but manufacturing complexity increases
Solution Approach 1:
The patent uses continuous fiber reinforced thermoplastic inserts that can be pre-formed and integrated into the main molding process. The composite insert provides both structural reinforcement and weight reduction, while the thermoplastic matrix allows for efficient manufacturing through injection molding techniques that automate insert placement and integration.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design achieves significant weight reduction, up to 42% compared to traditional aluminum designs, while maintaining mechanical performance and eliminating the need for metal inserts, thereby reducing costs.
Implementation Method 1
the composite reinforcement part forms a continuous load path in the inner structure enclosing a tailgate window opening for a window glazing part of the tailgate
Implementation Method 2
The composite reinforcement part is connected to a first surface of the inner structure, either by injection molding, overmolding, or adhesion by welding or gluing
Implementation Method 3
The composite reinforcement part is connected to a first surface of the inner structure, either by injection molding, overmolding, or adhesion by welding or gluing
Data Source
AI summary
The invention relates to a hybrid tailgate for a vehicle, comprising a thermoplastic inner structure forming the carrier frame of the tailgate, and at least one composite reinforcement part to reinforce the carrier frame, wherein the composite reinforcement part is connected to the thermoplastic inner structure at a first surface, wherein the composite reinforcement part forms a continuous load path in the inner structure enclosing a tailgate window opening for a window glazing part of the tailgate. Furthermore, the invention relates to a vehicle comprising such a hybrid tailgate. Moreover, the invention relates to a method of manufacturing such a hybrid tailgate, the method comprising forming a composite laminate part into an insert; placing the insert in an injection molding tool; and over-molding the insert with polymer resin.