Plastic Tailgate Structural Element Integrating Electrical Housing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing motor vehicle tailgates face challenges in optimizing manufacturing costs and integrating electrical components while maintaining structural rigidity and aesthetics, particularly in using traditional sheet metal structural elements.
Innovation Solution
A motor vehicle tailgate with a plastic structural element that includes an interior opening for housing electrical components, closed by a trim to provide additional functions and aesthetic options, allowing for the integration of rear optical elements like brake lights and indicators, reducing the need for external optical elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If sheet metal structural elements are used to ensure structural rigidity, then structural strength is improved, but manufacturing cost and integration of electrical components deteriorate
Solution Approach 1:
The patent changes the material parameter from sheet metal to plastic for the structural elements, while compensating for rigidity through geometric design (closed cross-section, elongated shape). This allows cost reduction and easier integration of electrical components while maintaining structural strength through optimized plastic element geometry rather than material substitution alone
Solution Approach 2:
The patent uses composite construction by combining plastic structural elements with trim pieces and electrical components within integrated housings. The plastic elements provide structural function while housing electrical components, and trim pieces provide aesthetic coverage, creating a multi-functional composite structure that reduces overall manufacturing cost
2Strength
If sheet metal structural elements with closed cross section are used to ensure rigidity, then structural strength is improved, but device complexity and integration of electrical components deteriorate
Solution Approach 1:
The patent merges multiple functions into the plastic structural elements: they provide structural support, house electrical components within their hollow interior, and integrate with trim pieces for aesthetic completion. This consolidation reduces device complexity by eliminating separate mounting structures and simplifying assembly operations
Solution Approach 2:
The plastic structural elements serve multiple functions simultaneously: structural support through their elongated closed-cross-section geometry, electrical component housing through their hollow interior space, and integration interfaces for trim pieces. This multi-functionality reduces overall system complexity compared to specialized separate components
3Ease of manufacture
If plastic structural elements with U-shaped section are used, then ease of manufacture is improved, but structural rigidity deteriorates
Solution Approach 1:
The patent segments the structural element into a U-shaped plastic profile that is then closed by integrating a trim piece or cover element. This segmentation allows the plastic element to be easily manufactured with open U-shape while the closing element provides the additional structural rigidity needed, combining manufacturing ease with structural strength
Solution Approach 2:
The patent enhances the rigidity of U-shaped plastic elements by adding structural reinforcement in the form of closing elements (trim pieces or covers) that complete the cross-section. This dimensional addition transforms the open U-shape into a closed section, significantly improving rigidity while maintaining the manufacturing advantages of the U-shaped plastic component
4Strength
If traditional sheet metal structural elements are used, then structural rigidity is maintained, but aesthetic configurations and integration of optical elements deteriorate
Solution Approach 1:
The patent changes the material parameter from sheet metal to plastic, which enables better aesthetic configurations through molding capabilities, integrated trim pieces, and seamless integration of optical elements. The plastic material allows for smoother surfaces, integrated lighting fixtures, and more flexible design options while maintaining structural rigidity through optimized geometry
Solution Approach 2:
The patent creates a composite aesthetic structure by combining plastic structural elements with decorative trim pieces and integrated optical elements (brake lights, indicators). This composite approach allows the structural element to provide rigidity while the trim and optical elements provide aesthetic functionality, creating a unified design that sheet metal cannot achieve
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The motor vehicle tailgate (10) comprises a plastic box structure comprising at least one structural element (16) supporting a rear screen (12). The structural element (16) delimits, with the rear screen (12), a housing (14) comprising an interior opening, the interior opening being closed by means of a lining (22) which is attached in such a way that the housing houses an electrical element of the vehicle.