Vehicle Tailgate Inner Box with Attachable Technical Panel

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Solution Overview

Problem

Current motor vehicle tailgate interior boxes, especially those made of thermoplastic and thermosetting plastic materials, face issues with mechanical fatigue, weight, and inefficient production processes due to machining requirements for recesses and functional integration, leading to material loss and increased production costs.

Innovation Solution

A two-part design for the interior box, comprising a frame and a separate, attachable central technical panel made of different materials, where the panel is produced using injection molding to integrate necessary features, reducing weight and eliminating the need for extensive machining.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If the inner box is made of thermoplastic material, then the weight is reduced and ease of manufacture is improved, but the mechanical strength and resistance to deformation deteriorate

Engineering Contradiction:

Improveweight of inner boxVSAvoidmechanical strength and resistance to deformation

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The inner box combines thermoplastic material (for weight reduction and ease of manufacture) with metal reinforcement elements (for mechanical strength and deformation resistance). The metal reinforcements are integrated into the thermoplastic structure, creating a composite system that achieves both light weight and high strength simultaneously.

Inventive Principle:

Principle #40Composite materials

2Strength

If the inner box is made of thermosetting plastic material, then the resistance to deformation is improved, but the weight increases and manufacturing complexity increases due to required machining operations

Engineering Contradiction:

Improveresistance to deformationVSAvoidweight of inner box

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The solution uses thermoplastic material as the base (lighter than thermosetting plastic) and adds metal reinforcement elements to provide the necessary deformation resistance. This composite approach avoids the weight penalty of using solid thermosetting plastic while maintaining structural integrity.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The inner box is divided into separate components: the thermoplastic housing and independently attachable metal reinforcement elements. This segmentation allows each component to be optimized for its specific function and enables assembly without extensive machining operations on the main body.

Inventive Principle:

Principle #1Segmentation

3Adaptability or versatility

If machining operations are performed on the inner box to create recesses and openings, then the functional integration is improved, but the material loss and production defects increase

Engineering Contradiction:

Improvefunctional integrationVSAvoidmaterial loss and production defects

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

Functional features such as recesses, openings, and mounting areas are created as separate molded features in the thermoplastic component rather than through machining. The metal reinforcement elements are designed to attach to these pre-formed features, eliminating the need for material removal and associated defects.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

All necessary functional features (recesses, openings, mounting interfaces) are incorporated into the thermoplastic mold design before production begins. This preliminary integration of functions eliminates the need for subsequent machining operations that would cause material loss and production defects.

Inventive Principle:

Principle #10Preliminary action

4Adaptability or versatility

If a complete inner box is manufactured to accommodate technical panel modifications, then the adaptability is improved, but the device complexity and production costs increase

Engineering Contradiction:

Improvetechnical panel modification capabilityVSAvoidproduction complexity and costs

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The inner box is segmented into the main thermoplastic housing and separate metal reinforcement elements. The technical panel can be modified independently, and the modular construction allows for easier adaptation without requiring complete remanufacturing of the entire inner box assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The metal reinforcement elements serve multiple functions: providing structural strength, creating mounting surfaces for technical panels, and enabling various configuration options. This multi-functionality allows the same basic structure to accommodate different technical panel modifications without increasing overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentEP3041698B1Inner box for a vehicle tailgate, with a technical panel fitted thereto

Publication Date: 2021.05.19 COMPAGNIE PLASTIC OMNIUM SA

Figure 1~2
Figure 3~4
Figure 5

AI summary

An inner box (3) for a motor vehicle tailgate, comprising a frame (7) and a set of technical elements (11, 12, 13, 14, 15) for components to pass through or be secured to, characterised in that said technical elements (11, 12, 3, 14, 15) are carried by a technical panel (10) fitted onto said frame (7).