Vehicle Rear Structure With Switchable Mold for Tailgate Variants

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Solution Overview

Problem

Existing vehicle body designs require separate tools and processes for various tailgate shapes, increasing production costs and reducing efficiency.

Innovation Solution

A rear structure of a vehicle body with a vehicle body rear complement including a rear cross member, back panel, and rear vertical panels, capable of accommodating various tailgate shapes, along with a mold system using trim cylinders for standardized production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If separate tools and production processes are used for various tailgate shapes, then consumer needs with diverse personalities are met, but production costs increase and production efficiency deteriorates

Engineering Contradiction:

Improvetailgate shape varietyVSAvoidproduction efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent applies universality by designing a single standardized rear structure that can accommodate multiple tailgate shapes (full lift-up, swing, and tailgate-less types). The rear cross member, back panel, and rear vertical panels form a universal platform with standardized opening flanges and sealing structures that work across different vehicle configurations, eliminating the need for separate production processes for each tailgate type.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent segments the vehicle body rear structure into modular components: rear cross member, back panel, rear vertical panels, and opening cover. This segmentation allows each component to be independently manufactured and assembled, enabling flexible configuration for different tailgate types while maintaining standardized production processes for each module.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If separate tools and production processes are used for various tailgate shapes, then consumer needs with diverse personalities are met, but production costs increase

Engineering Contradiction:

Improvetailgate shape varietyVSAvoidproduction cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The standardized rear structure serves as a universal platform for multiple tailgate configurations. By using the same rear cross member, back panel, and rear vertical panels with standardized opening flanges and sealing structures across different vehicle types, the patent reduces the need for specialized tools and processes, thereby lowering production costs while maintaining design variety.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges the production processes for different tailgate types into a single standardized process. The opening cover is designed with universal mounting structures that can be attached to the standardized rear structure using the same tools and assembly methods regardless of the specific tailgate configuration, consolidating manufacturing operations.

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If a standardized rear structure is used for various tailgate shapes, then production efficiency increases, but vehicle body strength and watertight performance must be maintained

Engineering Contradiction:

Improveproduction efficiencyVSAvoidwatertight performance

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent applies local quality by providing enhanced sealing features specifically at the opening flange locations where the opening cover interfaces with the rear structure. The sealing structures are strategically positioned at these critical interfaces to ensure watertight performance, while the rest of the standardized structure maintains production efficiency. The rear end surface is specifically designed with sealing capabilities at the tailgate opening perimeter.

Inventive Principle:

Principle #3Local quality

4Productivity

If a standardized rear structure is used for various tailgate shapes, then production efficiency increases, but vehicle body strength must be maintained

Engineering Contradiction:

Improveproduction efficiencyVSAvoidvehicle body strength

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The patent incorporates reinforcement structures and mounting portions directly into the standardized rear cross member and rear vertical panels during the initial manufacturing process. The rear mounting portions are pre-formed with appropriate thickness and structural features to accommodate hinge attachments and opening cover mounting, ensuring structural integrity is built-in from the start rather than requiring additional strengthening steps later.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20250222986A1Rear structure of vehicle body and mold system for producing of the same

Publication Date: 2025.07.10 HYUNDAI MOTOR CO LTD

AI summary

A rear structure of a vehicle body can include a vehicle body rear complement including a rear cross member, a back panel, and a rear vertical panel arranged on both sides of a vehicle body to connect the rear cross member and the back panel, and having a tailgate opening formed on an inner side thereof. A rear end surface that has an opening flange or sealing function can be formed along an outer edge of the tailgate opening on the inner side of the vehicle body rear complement. The rear end surface can be extending in a length direction or in a height direction of the vehicle body, depending on a target tailgate or tailgate-less configuration, which can be accomplished by switching one mold section of a plurality of molds in a mold system.