Tailgate Support Tube Hydroforming for Structural Integrity
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Solution Overview
Problem
Existing tailgate assemblies often require complex assemblies of multiple welded brackets for support, which increases assembly time and part complexity, and lack design flexibility in accommodating varying cross-sectional profiles for structural integrity.
Innovation Solution
A hydroformed U-shaped tube is used as a single monolithic structure extending along the inboard sides and bottom of the cargo bed access opening, providing structural support and varying cross-sectional profiles for enhanced strength and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple welded brackets are used for support, then structural support is provided, but assembly complexity and assembly time increase
Solution Approach 1:
The patent combines multiple separate support brackets into a single integrated tube structure that extends continuously along the inboard sides and bottom of the cargo bed access opening. This monolithic tube provides the same structural support function as multiple brackets while eliminating the need for separate components and welding operations, thereby reducing assembly complexity and time.
2Strength
If multiple welded brackets are used for support, then structural support is provided, but assembly time increases
Solution Approach 1:
The single integrated tube structure replaces multiple separate brackets, eliminating the time-consuming welding operations required to assemble multiple components. The tube can be installed as one piece, significantly reducing assembly time while maintaining the necessary structural support function.
3Ease of manufacture
If standard tubes are used, then manufacturing is simplified, but design flexibility for varying cross-sectional profiles is reduced
Solution Approach 1:
The tube is hydroformed to create varying cross-sectional profiles at different locations along its length. This allows the tube to have optimized structural properties in different regions - for example, larger cross-sections where higher strength is needed and smaller cross-sections where less support is required - while still being manufactured as a single integrated component through the hydroforming process.
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 hydroformed tube reduces assembly complexity, enhances structural integrity by accommodating different cross-sectional profiles, and facilitates easier integration with hinge assemblies and latches, improving the overall efficiency and design flexibility of the tailgate assembly.
Implementation Method 1
The tube can be hydroformed
Data Source
AI summary
A tailgate assembly includes a frame subassembly having a cargo bed access opening disposed between a driver side section and a passenger side section, and a door subassembly that is pivotably coupled to the frame subassembly and is pivotable relative to the frame subassembly back-and-forth between a door open position and a door closed position. The door subassembly closes the cargo bed access opening when the door subassembly is in the door closed position. The assembly further includes a tube of the frame subassembly. The tube extends along an inboard side of the driver side section, along an inboard side of the passenger side section, and along a bottom of the cargo bed access opening.