Liftgate Support Bracket Attachment for Blemish-Free Composite Panels
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Solution Overview
Problem
Existing methods for attaching support brackets to vehicle liftgate inner panels are time-consuming and prone to causing unwanted sink marks or blemishes on visible surfaces, and lack sufficient torque to support structural components like hinges and latches.
Innovation Solution
A liftgate support bracket connection arrangement using screws with shoulders and threaded shafts that align with bosses on the inner panel, providing a secure and blemish-free attachment by sliding through apertures in the support brackets and engaging with the panel's bosses, allowing for sufficient torque to support structural components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If adhesives or over-molding methods are used to attach brackets to the inner panel, then sink marks and blemishes on visible surfaces are prevented, but production time increases
Solution Approach 1:
The invention extracts the bracket attachment process from the visible surface area by positioning brackets on the rear side of the inner panel. The brackets extend forward only where necessary to provide structural support, keeping the attachment points and fasteners hidden from view. This allows the use of fasteners without creating visible blemishes on the front surface.
Solution Approach 2:
The invention introduces bosses as intermediary elements that protrude from the rear side of the inner panel. These bosses serve as attachment points for the brackets, allowing fasteners to engage with the panel structure without penetrating or adhering to the visible front surface. The bosses act as a mediator between the bracket attachment function and the aesthetic requirement of the visible surface.
2Productivity
If fasteners are used to attach brackets to the inner panel, then production time is reduced, but sink marks and blemishes may appear on visible surfaces
Solution Approach 1:
The invention relocates the fastener attachment points from the visible front surface to the hidden rear side of the inner panel. By positioning brackets and their associated fasteners on the rear side, the visible surface remains free of fastener holes, adhesive residue, or other attachment-related blemishes, while still achieving secure bracket attachment.
Solution Approach 2:
Instead of attaching brackets to the front or visible surfaces of the inner panel, the invention inverts the attachment approach by securing brackets to the rear side of the panel. This reversal of the attachment location allows fasteners to be used without compromising the aesthetic appearance of the visible surface.
3Weight of moving object
If the inner panel is constructed from lighter composite materials, then vehicle weight is reduced, but structural strength and support capability are compromised
Solution Approach 1:
The invention utilizes composite inner panels with integrated bosses that provide both weight reduction and structural reinforcement. The bosses, formed as part of the composite panel structure, serve as attachment points for brackets while maintaining the overall lightweight composite construction of the inner panel.
Solution Approach 2:
The bosses are pre-formed as integral parts of the composite inner panel during the panel manufacturing process. This preliminary formation of attachment points eliminates the need for additional reinforcement elements or post-assembly strengthening, maintaining weight efficiency while ensuring structural capability for bracket attachment.
4Strength
If reinforcement brackets are added to strengthen the inner panel, then structural integrity is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The invention merges the reinforcement bracket function with the inner panel structure itself by forming bosses as integral parts of the composite panel. This integration eliminates the need for separate reinforcement elements and simplifies the overall structure, as the bosses serve both as structural features and as attachment points for brackets.
Solution Approach 2:
The bosses serve multiple functions: they provide structural reinforcement to the composite inner panel, serve as attachment points for brackets, and maintain the lightweight composite construction. This multi-functionality reduces the need for additional components and simplifies the overall device complexity.
Data Source
AI summary
A liftgate support bracket connection arrangement for a vehicle liftgate. The liftgate can be for a rear vehicle liftgate or any other type of liftgate found on a vehicle. Connected to the composite inner panel are support brackets. The inner panel of a liftgate has a plurality of bosses formed on an outer surface of the inner panel. Each of the support brackets has a plurality of apertures corresponding in number to the plurality of bosses. Each one of the plurality of apertures is configured to align with one of the plurality of bosses and then screws are used to mechanically fasten the support bracket to the inner panel.