Modular Vehicle Rear Assembly for Easier Trim Fastening

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Solution Overview

Problem

The existing methods for assembling motor vehicle rears are cumbersome due to the large weight and complexity of the rear trim parts, which are typically fastened as a single, continuous unit, making it difficult to access fastening points and increasing assembly effort.

Innovation Solution

Divide the rear trim part into three separate assemblies (two side parts and a center part) that are independently fastened to the frame or sheet-metal structure, allowing for easier access and reduced weight, with pre-mounted units such as charging and air-guiding modules simplifying the assembly process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If the rear trim part is made as a single continuous unit extending over the entire width of the motor vehicle rear, then the outer skin is continuously covered, but the assembly becomes cumbersome due to large weight and difficult access to fastening points

Engineering Contradiction:

Improvecontinuity of outer skin coverageVSAvoidassembly ease

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The rear trim part is divided into multiple separate assemblies (first rear side part, second rear side part, and rear center part) that can be independently fastened to the frame structure. This segmentation reduces the weight of individual components, improves accessibility to fastening points, and simplifies the assembly process while still providing continuous coverage when assembled together.

Inventive Principle:

Principle #1Segmentation

2Strength

If the rear trim part is made as a single continuous unit, then structural integrity is maintained, but the weight increases making fastening more difficult

Engineering Contradiction:

Improvestructural integrityVSAvoidweight of rear trim part

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The rear trim part is divided into multiple separate assemblies (first rear side part, second rear side part, and rear center part) that can be independently fastened to the frame structure. This segmentation reduces the weight of individual components, making them easier to handle and fasten, while the overall structural integrity is maintained through proper connection design between segments.

Inventive Principle:

Principle #1Segmentation

3Productivity

If the rear trim part is divided into separate assemblies, then assembly effort is reduced and weight is decreased, but the number of components increases

Engineering Contradiction:

Improveassembly efficiencyVSAvoidnumber of assemblies

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The rear trim part is divided into a manageable number of separate assemblies (first rear side part, second rear side part, and rear center part), which improves assembly efficiency by reducing weight and improving accessibility. The segmentation is optimized to balance the benefit of easier assembly against the increase in component count, creating a practical solution rather than excessive fragmentation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple functional modules (charging flap module, air-guiding module) are pre-mounted on the rear side parts as integrated units. This merging of functions into pre-assembled modules reduces the overall assembly complexity by minimizing the number of separate fastening operations required, as entire functional assemblies are installed as single units.

Inventive Principle:

Principle #5Merging (Combining)

4Ease of manufacture

If charging flap modules and air-guiding modules are pre-mounted on rear side parts, then assembly is simplified, but the weight of individual assemblies increases

Engineering Contradiction:

Improveassembly simplicityVSAvoidweight of rear side part with modules

Core Design Contradiction:

Ease of manufactureVSWeight of moving object

Solution Approach 1:

Multiple functional modules (charging flap module, air-guiding module) are pre-mounted on the rear side parts as integrated units. This merging of functions into pre-assembled modules simplifies the final assembly process by reducing the number of separate fastening operations required, as entire functional assemblies are installed as single units. The weight increase is accepted as a trade-off for the significant reduction in assembly complexity and time.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20240158017A1Motor vehicle rear and method for assembling a motor vehicle rear

Publication Date: 2024.05.16 DR ING H C F PORSCHE AG

AI summary

A motor vehicle rear, with a rear cover defining in sections an outer skin of the motor vehicle rear. A first rear side part defines in sections the outer skin of the motor vehicle rear laterally beside the rear cover on a first side thereof. A second rear side part defines in sections the outer skin of the motor vehicle rear laterally beside the rear cover on a second side thereof. A rear center part defines the outer skin of the motor vehicle rear below the rear cover, wherein the first rear side part, the second rear side part, and the rear center part are formed as separate assemblies and are separately fastened on a frame structure or sheet-metal structure of a shell of the motor vehicle rear.