Vehicle Tailgate Leakage Prevention via Integral Spoiler Bonding

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Solution Overview

Problem

Conventional tailgates for vehicles with large overall height suffer from leakage issues at the combined parts of the spoiler and back panel, which affects driving stability and increases costs due to the use of steel, while also being heavy and lacking in robustness.

Innovation Solution

A tailgate design featuring a body panel with an internal panel and a cover panel made of polypropylene and talc, integrated with a spoiler portion, reinforced by side and center reinforcing members, bonded using an adhesive, which includes a lamp device and is manufactured by heat-processing sections before bonding to prevent leakage and enhance robustness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the spoiler is combined with the back panel through bolts and fasteners, then the structural strength is improved, but leakage occurs at the combined part

Engineering Contradiction:

Improvestructural strengthVSAvoidleakage prevention

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The spoiler and cover panel are integrated into a single integrally-formed component, eliminating the joint between separate parts that caused leakage. This merging removes the interface where leakage occurred while maintaining structural strength through the integral design.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mechanical connection method using bolts and fasteners is replaced with an integral formation method where the spoiler and cover panel are formed as one piece. This substitution eliminates the need for mechanical fasteners at the joint, preventing leakage while maintaining structural integrity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If steel is used for the tailgate, then the robustness is improved, but the weight and manufacturing costs increase

Engineering Contradiction:

ImproverobustnessVSAvoidtailgate weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The tailgate uses a composite structure combining an internal panel (steel or other material) with a cover panel made of plastic material. This composite approach reduces weight compared to solid steel while maintaining robustness through the reinforced internal panel structure and strategic placement of reinforcing members.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Instead of using uniform steel throughout, the invention applies reinforcement locally through strategically positioned reinforcing members (side reinforcing members and center reinforcing members) that provide structural strength only where needed, reducing overall weight while maintaining robustness.

Inventive Principle:

Principle #3Local quality

3Strength

If conventional bolting methods are used to assemble the tailgate, then the assembly strength is improved, but the manufacturing complexity and cost increase

Engineering Contradiction:

Improveassembly strengthVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The spoiler and cover panel are merged into a single integrally-formed component, reducing the number of parts and assembly steps. This eliminates the complexity of aligning and fastening multiple separate components while maintaining assembly strength through the integral design.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Mechanical fastening systems (bolts and fasteners) are replaced with adhesive bonding for attaching the cover panel to the body panel. This substitution simplifies the assembly process by eliminating the need for precise alignment and mechanical fasteners, reducing manufacturing complexity while maintaining assembly strength.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 reduces weight and costs, improves driving stability by preventing leakage, and increases the robustness of the tailgate, while maintaining an elegant design and efficient assembly process.

Implementation Method 1

a cover panel (120) mounted on the body panel (110) by an adhesive (140)

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Implementation Method 2

heat-processing a section of the body panel where the cover panel is mounted before bonding the cover panel on the body panel

Methodology Applied

Scientific EffectHeat treatment: Heat Treatment

Implementation Method 3

at least one reinforcing member disposed on a side of the cover panel facing the body panel

Methodology Applied

Scientific EffectStructural reinforcement:

Data Source

PatentUS10272749B2Tailgate for vehicle and method for manufacturing the same

Publication Date: 2019.04.30 HYUNDAI MOTOR CO LTD

AI summary

A tailgate for vehicle may include a body panel including an internal panel and a reinforcing panel mounted on at least a portion of the internal panel, a cover panel mounted on the body panel by an adhesive to cover a portion of the body panel and having a cover body integrally formed with a spoiler portion, and a lamp device mounted on the cover panel.