Tailgate Gap Sealing with Inserted Filling Part
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Solution Overview
Problem
Existing sealing methods for the angled edge areas of motor vehicle tailgates, such as PVC hem flange seals, are inadequate for sealing larger gaps, leading to moisture penetration and corrosion, and manual reworking is time-consuming and unreliable, preventing fully automatic production.
Innovation Solution
A sealing device with a gap-filling part that is introduced into the gap between the outer and inner walls of the tailgate, which can be gripped and positioned automatically, and optionally sealed with a PVC flange seal, to ensure a watertight closure of the gap, using a central fastening groove and spring tongue mechanism for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a PVC hem flange seal is used to seal the gap, then the sealing process can be automated, but larger gaps cannot be sealed watertight
Solution Approach 1:
The sealing solution is divided into two functional segments: a gap-filling part (such as foam material) that addresses larger gaps, and a PVC hem flange seal that provides watertight sealing for smaller remaining gaps. This segmentation allows each component to optimize its function, enabling both automation and reliable watertight sealing even for larger gaps.
2Reliability
If manual reworking is used to fill PVC into side gaps, then sealing quality can be maintained, but production time increases and process reliability decreases
Solution Approach 1:
The gap-filling part is pre-formed and automatically inserted into the gap before the final sealing step. This preliminary action prepares the gap for subsequent watertight sealing, eliminating the need for manual PVC filling while maintaining sealing quality and enabling automated high-speed production.
3Productivity
If the gap is left unsealed, then production speed is maximized, but moisture penetration and corrosion occur
Solution Approach 1:
The gap-filling part is designed to automatically expand or conform to the gap dimensions once inserted, requiring no manual adjustment or additional processing. This self-service characteristic enables automated insertion while ensuring adequate gap filling, thereby preventing moisture penetration without compromising production speed.
Data Source
Figure 1~2
AI summary
Sealing device for an opening in the shell of a flap, in particular a tailgate of a motor vehicle, which has a flap outer wall (2) with at least two outer wall parts (5, 6), which respectively have on facing circumferential wall regions an inwardly angled-away peripheral region (7, 8), which peripheral regions are connected to one another. With a flap inner wall (3), which has at least one inner wall part (11), which is connected at a distance from the angled-away peripheral regions (7, 8) of the outer wall parts (5, 6) to at least one circumferential region (9, 10) of the flap outer wall (2) and, in the region of the angled-away peripheral regions (7, 8) of the outer wall parts (5, 6), forms a gap (1) together with the flap outer wall (2). Before the flap outer wall (2) is connected to the flap inner wall (3), a gap filling part (4) is brought into a closing position and, after the flap outer wall (2) is connected to the flap inner wall (3), seals the gap (1) on its own or together with a gap sealing means.