Vehicle Tailgate Sill Flap Roller Mechanism
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing vehicle tailgate designs face challenges in accommodating spare tire bins and other components under the cargo bed, particularly due to space constraints and unconventional bed shapes, which complicates the design of compatible sill flaps and leads to friction damage during opening and closing.
Innovation Solution
A vehicle tailgate assembly featuring a sill flap with rollers that contact the tailgate, allowing the sill flap to pivot and open into the gap between the tailgate and the bed, preventing frictional contact and enabling the tailgate and sill flap to lie flat as an extension of the vehicle bed, with cutouts for accommodating various bed shapes and components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the tailgate is designed to pivot about an axis at or proximate to the lower end of the tailgate panel, then a small gap between the open tailgate and the bed is achieved, but the useful length of the cargo bed is reduced when the tailgate is open
Solution Approach 1:
A sill flap is introduced as an intermediary component between the tailgate and the cargo bed. The sill flap pivots about an axis spaced from the tailgate's lower end, allowing it to extend into the gap created by the tailgate's wide-throw opening, thereby maintaining the useful length of the cargo bed while accommodating the tailgate's pivoting motion
2Length of stationary object
If wide-throw or swing-clear hinges are used to leave an offset or gap between the tailgate panel and the end of the cargo bed, then the useful length of the cargo bed is extended when the tailgate is open, but an additional tailgate component such as a sill flap is required
Solution Approach 1:
The sill flap is designed to serve multiple functions: it acts as a cover for the cargo bed, provides structural support, and mechanically interfaces with the tailgate through roller contacts. By integrating these functions into a single component, the overall device complexity is reduced despite the wide-throw hinge configuration
3Length of stationary object
If a sill flap is added to cover the gap when the tailgate is open, then the useful length of the cargo bed is maintained, but space constraints under the vehicle bed and the sizes and shapes of various vehicle components located there may dictate unconventional bed shapes that present difficulties in designing compatible sill flaps
Solution Approach 1:
The sill flap's pivot axis is positioned at a specific distance from the tailgate's lower end, creating a controlled arc of motion. This parameter adjustment allows the sill flap to adapt to various bed shapes and component configurations, as the pivot point and arc can be optimized to clear specific obstacles while maintaining cargo bed coverage
4Ease of operation
If the sill flap and tailgate are opened by pivoting from their upright closed configuration, then the tailgate and sill flap can lie flat to act as an extension of the vehicle bed, but sliding contact between the sill flap and tailgate causes friction damage
Solution Approach 1:
Rollers are introduced as intermediary elements between the sill flap and the tailgate. These rollers convert the sliding contact that causes friction damage into rolling contact, significantly reducing wear and damage while allowing the sill flap to pivot into its open position and lie flat against the tailgate
Solution Approach 2:
The sliding friction mechanism is replaced with a rolling contact mechanism. By substituting the direct sliding interface with rollers, the harmful frictional forces are dramatically reduced, allowing smooth operation of the tailgate and sill flap assembly
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
This configuration allows for a larger, flexible cargo bed area, reduces friction and wear, and accommodates various vehicle components by maintaining rolling contact between the sill flap and tailgate, while providing greater clearance for components like spare tire bins and larger batteries.
Implementation Method 1
the sill flap has one or more rollers facing the tailgate. The rollers thus rotate along the tailgate while the sill flap and the tailgate are pivoted between a closed vehicle bed orientation and an open vehicle bed orientation
Data Source
AI summary
Vehicle tailgate assembly that includes a sill flap and tailgate, where the sill flap has rollers that contact the tailgate while the sill flap and tailgate are opened or closed. The sill flap thus maintains rolling contact with the tailgate during opening and closing operations. In embodiments of the disclosure, the tailgate opens to leave a gap between the edge of the vehicle bed and the edge of the tailgate, and the sill flap is pivoted into this gap. While being pivoted into this open position, the sill flap rollers rotatably contact the tailgate, so that the sill flap maintains rolling contact with the tailgate rather than frictional contact therewith. This prevents damage to the sill flap and tailgate when opened and closed.