Integrated Tail Gate Panel Spoiler Design
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Solution Overview
Problem
Current manufacturing methods for motor vehicle tail gate panels are costly and inefficient due to the need for additional spoilers and complex surface treatments, which limit the aerodynamic performance and increase production time and weight.
Innovation Solution
A motor vehicle tail gate panel design that integrates a spoiler-like section into the box, extending beyond the adhesion area, made from composite materials with thermosetting plastic and reinforcement ribs, providing good aerodynamics without separate spoiler manufacturing and reducing weight and air resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a separate spoiler is attached or adhered to the glass or box, then aerodynamic performance is improved, but manufacturing cost increases and production time extends
Solution Approach 1:
The spoiler is integrated directly into the box structure as an extension of the box walls, eliminating the need for separate spoiler components and their associated attachment operations. The box extends beyond the adhesion area to form spoiler sections that are structurally unified with the box, thereby simplifying manufacturing while maintaining aerodynamic performance.
2Object-affected harmful factors
If a separate spoiler is attached or adhered to the glass or box, then aerodynamic performance is improved, but production cost increases
Solution Approach 1:
The spoiler sections are formed as integral extensions of the box structure during the same manufacturing process, eliminating the need for separate spoiler manufacturing, procurement, and attachment operations. This integration reduces material costs, labor costs, and overhead associated with multi-component assembly.
3Object-affected harmful factors
If the box is extended beyond the adhesion area to form spoiler sections, then aerodynamic performance is improved, but the box structure becomes more complex
Solution Approach 1:
The box structure is divided into functional zones: the adhesion area for glass mounting and the extended spoiler sections for aerodynamic performance. This segmentation allows each zone to be optimized independently while maintaining overall structural integrity through the composite material construction.
Solution Approach 2:
The box exhibits different structural characteristics in different regions: the adhesion area is optimized for glass bonding while the extended spoiler sections are shaped for aerodynamic efficiency. The composite material construction allows local variation in thickness, reinforcement, and geometry to meet specific functional requirements.
4Strength
If separate spoilers and metal inserts are used, then structural strength is ensured, but vehicle weight increases
Solution Approach 1:
The box and integrated spoiler sections are constructed from composite materials that provide high strength-to-weight ratio, eliminating the need for metal inserts and separate spoiler components. The composite structure maintains structural integrity while significantly reducing overall weight compared to traditional metal-based assemblies.
Data Source
AI summary
A motor vehicle tail gate panel has one side facing the inside of the motor vehicle and one side facing the outside of the motor vehicle and including a box having an adhesion area on the side facing the outside of the motor vehicle for adhering a glass to the surface of the box. The box extends beyond the adhesion area on the side opposite this area so as to form at least one section that is visible from the outside of the motor vehicle, and the section has a shape that enhances the aerodynamics of the motor vehicle. As a result, additional spoilers may not be needed, which improves productivity and reduces production costs. Example embodiments also relate to a motor vehicle that includes the tail gate panel.