Multi-Shot Plastic Tailgate Glazing for Seamless Light Integration
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Solution Overview
Problem
Existing tailgates and vehicle components face challenges such as increased complexity and cost due to numerous separate components, inhomogeneities, seams, and aerodynamic inefficiencies, as well as aesthetic issues like exposed adhesives and concealed components.
Innovation Solution
The development of a plastic glazing for tailgates with integrated textures or patterns, formed through multi-shot injection molding, which reduces the number of components, conceals vehicle features, and enhances aesthetic and aerodynamic performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If multiple separate components (lamps, housings, lenses, substrates) are used in light assemblies, then functional requirements can be met, but device complexity and assembly cost increase
Solution Approach 1:
The patent combines multiple separate light assembly components (lamps, housings, lenses, substrates) into a single integrated light assembly unit. This merging eliminates the need for separate components and their associated assembly operations, directly reducing device complexity and assembly cost while maintaining all necessary lighting functions.
Solution Approach 2:
The integrated light assembly is designed to perform multiple functions simultaneously - housing multiple different types of lights (parking, turn indicator, brake lights), providing structural support, and serving as a mounting substrate. This multi-functionality consolidates what would otherwise require multiple separate components into one universal assembly.
2Device complexity
If separate vehicle components are used, then functional requirements are met, but inhomogeneities and seams increase affecting aesthetics and aerodynamics
Solution Approach 1:
The patent merges multiple separate vehicle components into a single integrated component with a continuous outer surface. This eliminates seams and inhomogeneities at component interfaces, improving both aesthetic appearance and aerodynamic performance by creating a smooth, unified surface.
3Shape
If adhesive films are used to conceal seals and wires, then aesthetic appearance is improved, but the film may detach over time exposing concealed components
Solution Approach 1:
The patent removes the need for separate adhesive films by integrating the concealment function directly into the molded plastic structure. The textured or patterned surface is formed as an inherent part of the component during molding, eliminating the separate adhesive layer that could detach and exposing no concealed components.
4Device complexity
If integrated light assembly structure is used, then device complexity is reduced, but haziness issues and color overlap occur
Solution Approach 1:
The patent applies different surface properties to different regions of the integrated light assembly. Specific areas have textured or patterned surfaces that control light direction and prevent haziness, while other areas remain smooth or have different optical properties to prevent color overlap. This localized differentiation maintains manufacturing precision within the integrated structure.
Data Source
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.