Integrated Plastic Glazing for Tailgate Lighting

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Solution Overview

Problem

Conventional vehicle tailgate lighting systems are complex and costly due to numerous separate components, which increase weight, complexity, and aerodynamic inefficiencies, and fail to meet regulatory lighting requirements, especially when using colored plastics that cause color overlap and haziness issues.

Innovation Solution

A tailgate with integrated plastic glazing that functions as both a lens and a structural component, using a one-piece molded construction with colored regions to prevent color overlap and reduce component count, supported by a housing unit that eliminates the need for separate light housings and lenses, and manufactured using injection molding to streamline production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple separate light assemblies are used in the tailgate, then lighting functionality is achieved, but component count and assembly complexity increase

Engineering Contradiction:

Improvelighting functionalityVSAvoidcomponent count

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent integrates multiple light assemblies (brake lights, turn signals, reverse lights) into a single molded plastic glazing component. Different regions of the glazing contain different light sources and lenses, combining what were previously separate assemblies into one unified structure that reduces part count while maintaining all required lighting functions

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The plastic glazing serves multiple functions simultaneously: it acts as a structural tailgate component, a lens for light transmission, a housing for light sources, and a regulatory compliance element. This multi-functionality eliminates the need for separate dedicated components for each function

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If conventional separate light assemblies with housings and lenses are used, then lighting is achieved, but vehicle weight increases

Engineering Contradiction:

Improvelighting performanceVSAvoidvehicle weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The housing, lens, and light source mounting structures are merged into a single molded plastic glazing component. This integration eliminates the weight of multiple separate parts and their fastening hardware, while the plastic material provides sufficient structural support for all lighting functions

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If separate vehicle components are used for tailgate assembly, then functionality is achieved, but aerodynamic efficiency decreases due to seams and openings

Engineering Contradiction:

Improvetailgate functionalityVSAvoidaerodynamic inefficiency

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The plastic glazing is molded as a seamless integrated component that forms part of the tailgate body. This eliminates gaps, seams, and openings between separate parts that would create aerodynamic drag, while still providing all necessary structural and lighting functions through the unified design

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If colored plastic components are used in light assemblies, then color coding is achieved, but color overlap and haziness issues occur

Engineering Contradiction:

Improvelight color identificationVSAvoidcolor accuracy

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

Different regions of the plastic glazing are molded with specific local colors (red for brake lights, amber for turn signals, clear for reverse lights). Each colored region is precisely positioned to correspond with its associated light source, preventing color overlap and ensuring that each light type projects its correct color without interference from adjacent colored plastics

Inventive Principle:

Principle #3Local quality

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 solution reduces the number of vehicle components, enhances aesthetic appeal, improves aerodynamics, and ensures compliance with regulatory lighting standards by integrating lighting functions into the tailgate's plastic glazing, while also potentially replacing heavier glass components with lighter, stronger plastic.

Implementation Method 1

a first colored portion 102 that transmits a light of a first color, a second colored portion 104 that transmits a light of a second color

Methodology Applied

Scientific EffectLight transmission: Light

Data Source

PatentUS10948152B2Lighting systems of tailgates with plastic glazing

Publication Date: 2021.03.16 SABIC GLOBAL TECHNOLOGIES BV

AI summary

A plastic glazing of a tailgate of a vehicle is provided, the plastic glazing comprising: a first translucent component; a second translucent component molded onto the first translucent component, wherein the second translucent component comprises a color, wherein the plastic glazing is of one-piece molded plastic construction, wherein an overlapping portion of the first translucent component and the second translucent component forms a lens of a first molded light assembly.