Resin Tailgate Hinge Reinforcement Closed Cross-Section
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Solution Overview
Problem
Existing tailgate structures made of resin often deform when subjected to heavy loads due to the opening of C-shaped hinge reinforcements, leading to instability and loss of rigidity.
Innovation Solution
A tailgate structure with a hinge reinforcement member forming a closed cross-section by connecting the tip ends of sidewalls, which transfers heavy loads to the vehicle body, inhibiting opening deformation and ensuring rigidity without the need for additional members, and incorporating a sidewall reinforcement portion to enhance strength and reduce manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a C-shaped hinge reinforcement is used to support the tailgate, then the structure is simple and easy to manufacture, but the reinforcement deforms under heavy load causing the tailgate to deform
Solution Approach 1:
The hinge reinforcement is divided into multiple segments: a pair of side portions extending along the sidewalls of the window frame, and a connecting portion joining these side portions. This segmentation allows each part to perform its specific function - the side portions provide lateral support while the connecting portion prevents opening deformation, collectively enhancing the overall strength without complicating the manufacturing process.
Solution Approach 2:
The connecting portion of the hinge reinforcement is configured with a curved shape that extends from one side portion to the other, forming a substantially U-shaped or arch-like structure. This curvature provides structural efficiency by distributing loads more effectively and resisting the opening forces applied to the tailgate, thereby preventing deformation while maintaining a simple integrated design.
2Weight of moving object
If resin is used for the window frame portion, then weight is reduced and manufacturing is simplified, but rigidity is insufficient under heavy load
Solution Approach 1:
The tailgate employs a composite structure combining resin material for the window frame portion with metallic hinge reinforcements. The resin provides lightweight properties and corrosion resistance, while the metal reinforcements embedded within or attached to the resin structure provide the necessary strength and rigidity to withstand heavy loads, creating a synergistic composite system that balances weight and structural performance.
Solution Approach 2:
The hinge reinforcement is strategically positioned at critical locations where loads are applied to the tailgate - specifically along the sidewalls and connecting the top corners. This localized reinforcement provides strength exactly where needed to prevent opening deformation, while the rest of the window frame can remain lightweight resin, optimizing the overall weight-strength balance through non-uniform material distribution.
Data Source
AI summary
Even when a heavy load is applied to a tailgate of resin, deformation of the tailgate is inhibited. The tailgate includes a window frame portion of resin forming a window opening portion. The window frame portion includes a bottom wall located on the vehicle interior side, and an outer sidewall and an inner sidewall each of which extending from the corresponding either one end of the bottom wall. The tailgate connects the exterior ends of an outer sidewall and an inner sidewall to form a closed cross-section, and includes a hinge reinforcement member fitted to a hinge mechanism. The hinge reinforcement member includes an outer sidewall reinforcement portion along the outer sidewall. The hinge member is fastened to the outer sidewall reinforcement portion and the outer sidewall together by a connection bolt and a nut.