Multi-Shot Plastic Tailgate With Integrated Window and Light Regions

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Solution Overview

Problem

The existing tailgate designs for vehicles are complex and costly due to multiple components, inhomogeneities, and aerodynamic inefficiencies, which affect the aesthetic appeal and functionality, particularly with light assemblies and window sealing.

Innovation Solution

A one-piece molded plastic tailgate with integrated components, including a translucent rear window and non-transparent blackout regions, using multi-shot injection molding to reduce components and seams, and incorporating textured or patterned surfaces to conceal wiring and adhesives, thereby simplifying assembly and enhancing aesthetics and aerodynamics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple separate components (light assemblies, window, seals) are used in tailgate design, then functional requirements can be met, but device complexity and assembly cost increase

Engineering Contradiction:

Improvefunctional requirementsVSAvoidnumber of components

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent integrates multiple separate components (light assemblies, window, seals, wiring) into a single molded plastic tailgate component. The light assemblies are embedded directly into the molded structure, the window is integrated with gaskets and seals, and wiring is concealed within the molded body, eliminating the need for separate mounting brackets, fasteners, and assembly steps.

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If separate vehicle components are assembled together, then functional requirements are met, but inhomogeneities and seams appear affecting aesthetic appearance

Engineering Contradiction:

Improvefunctional requirementsVSAvoidaesthetic appearance

Core Design Contradiction:

Adaptability or versatilityVSShape

Solution Approach 1:

The patent creates a seamless, homogeneous appearance by integrating all components into a single molded structure. The molded plastic body eliminates visible seams between light assemblies, window frames, and seals. The textured surface patterns further conceal any minor imperfections, achieving a uniform aesthetic appearance while maintaining all required functions.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If separate vehicle components are assembled together, then functional requirements are met, but aerodynamic inefficiencies occur

Engineering Contradiction:

Improvefunctional requirementsVSAvoidaerodynamic inefficiencies

Core Design Contradiction:

Adaptability or versatilityVSObject-generated harmful factors

Solution Approach 1:

The patent achieves aerodynamic efficiency by creating a smooth, continuous outer surface through single-piece molding. The integrated design eliminates gaps, seams, and protruding fasteners that would disrupt airflow. The molded structure allows for optimized aerodynamic contours while incorporating all necessary functional elements internally.

Inventive Principle:

Principle #5Merging (Combining)

4Device complexity

If light assemblies are integrated without sidewalls or reflectors, then device complexity is reduced, but haziness issues and color overlap occur

Engineering Contradiction:

Improvenumber of partsVSAvoidlight control precision

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent applies different properties to different regions of the molded plastic body. Specific areas incorporate optical features such as diffusers, reflectors, and color-tinted sections to control light distribution. The molding process integrates these optical elements directly into the structure, providing precise light control in localized regions while maintaining overall design simplicity.

Inventive Principle:

Principle #3Local quality

5Shape

If adhesive film is used to conceal seals and wiring, then aesthetic appearance is improved, but the film detaches over time exposing concealed components

Engineering Contradiction:

Improveaesthetic appearanceVSAvoidconcealment durability

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The patent integrates the concealment function directly into the molded plastic structure itself. The textured surface patterns and molded features permanently embed the concealment of seals and wiring, eliminating the need for separate adhesive films. This integrated approach ensures long-term durability as the concealment is structurally bonded rather than surface-adhered.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11845240B2Three shot plastic tailgate

Publication Date: 2023.12.19 SABIC GLOBAL TECHNOLOGIES BV

AI summary

A plastic glazing of a tailgate of a vehicle is provided, the plastic glazing comprising a translucent component, wherein a portion of the translucent component forms a rear window of the vehicle, a colored component molded onto the translucent component in a second shot, wherein the colored component comprises a lens of a light unit, a non-transparent component molded onto the translucent component, wherein an overlapping portion of the translucent component and the non-transparent component forms a blackout region proximate to the rear window, wherein the plastic glazing is of one-piece molded plastic construction, wherein the translucent component comprises a first textured surface in a region adjacent to the blackout region, where the first textured surface is configured to conceal a component of the vehicle.