Polyethylene Tailgate Spreader with Electric Drive
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Solution Overview
Problem
Existing replaceable tailgate spreaders are heavy, expensive, prone to corrosion, and require hydraulic power, limiting their use and increasing installation costs due to the need for hydraulic systems and professional installation.
Innovation Solution
A lightweight, corrosion-resistant polyethylene tailgate spreader with a 12-volt electric drive system that is easily installed on vehicles, using a plastic hopper and electric motor, and includes a vibrator for material flow facilitation, reducing installation complexity and environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If carbon or stainless steel construction is used for the spreader, then strength and durability are improved, but weight and cost increase significantly
Solution Approach 1:
The spreader uses a composite construction with a polyethylene hopper and frame members, combining the corrosion resistance and lightweight properties of plastic with the structural support needed for tailgate mounting. This replaces traditional all-metal construction while maintaining strength requirements.
2Strength
If carbon or stainless steel construction is used for the spreader, then strength and durability are improved, but manufacturing cost increases
Solution Approach 1:
The polyethylene hopper and frame members provide a cost-effective alternative to carbon or stainless steel construction. The plastic components can be manufactured using molding processes, reducing fabrication costs while maintaining adequate structural strength for the application.
3Ease of manufacture
If carbon steel construction is used for the spreader, then initial cost is reduced, but corrosion resistance deteriorates when spreading salt
Solution Approach 1:
The polyethylene material provides inherent corrosion resistance when spreading salt and other corrosive materials, eliminating the rust problems associated with carbon steel. The plastic construction maintains reliability in corrosive environments while keeping costs lower than stainless steel alternatives.
4Power
If hydraulic power system is used for the spreader, then power availability is improved, but system complexity and installation cost increase
Solution Approach 1:
The hydraulic motor system is replaced with an electric motor powered by the vehicle's electrical system. This substitution eliminates the need for hydraulic lines, pumps, and reservoirs, significantly reducing system complexity while maintaining adequate power for auger and spinner operation.
5Power
If hydraulic power system is used for the spreader, then power availability is improved, but installation difficulty and professional installation requirement increase
Solution Approach 1:
Replacing the hydraulic system with an electric motor system eliminates the need for complex hydraulic line routing and professional installation. The electric motor connects directly to the vehicle's electrical system through simple wiring, enabling easier installation by non-professionals.
6Power
If hydraulic power system is used for the spreader, then power availability is improved, but environmental harm from fluid leaks increases
Solution Approach 1:
The electric motor system eliminates hydraulic fluid entirely, removing the source of environmental contamination from leaks. This substitution maintains power availability for spreader operation while eliminating the harmful effects of hydraulic fluid on the environment and vehicle components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a cost-effective, easy-to-install spreader that can be used on various vehicles without hydraulic power, maintaining an even spread pattern and reducing environmental hazards from hydraulic fluid leaks.
Implementation Method 1
The vibrator includes a vibratory motor connected to a v-shaped plate to create a chiseling effect to produce continual flow
Data Source
AI summary
A plastic tailgate mounted spreader adapted to replace the tailgate of a vehicle. The tailgate mounted spreader has a plastic hopper having a width and height generally equal to the width and height of the vehicle tailgate. A frame having at least a top member and a bottom member supports the hopper. In the disclosed embodiment, the frame also includes side members. The top member has first and second arms extending from the top member that are adapted to be connected to the vehicle. The bottom member has first and second rods extending from the bottom member that are adapted to be connected to the vehicle and in particular to the clamps on the vehicle that control the release of the bucket. An auger is mounted within the plastic hopper to auger material to a discharge opening. The auger is mounted between the side members in the preferred embodiment. A material spinner and motor assembly are pivotally mounted below the discharge opening of the hopper so the material spinner and motor pivots with respect to the vehicle to remain generally horizontal with respect to the vehicle.