Motor Vehicle Tailgate U-Shaped Frame Weight Reduction
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Solution Overview
Problem
Existing motor vehicle tailgates with fully surrounding frames to protect transparent panels from damage become excessively heavy due to the added weight of the frame, compromising vehicle performance.
Innovation Solution
A tailgate design featuring a U-shaped support frame with reinforced plates and members only at mechanically stressed areas, using a metallic material and forming the frame in one piece to enhance mechanical strength while minimizing weight, and incorporating openings for further weight reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a frame completely surrounds the transparent panel, then the mechanical strength and protection of the transparent panel is improved, but the weight of the tailgate increases significantly
Solution Approach 1:
The frame is segmented into different sections with varying thicknesses: thicker at the periphery and at specific reinforcement locations (hinge areas, locking mechanisms), and thinner in between. This segmentation allows the frame to provide maximum strength where needed while reducing weight in less critical areas, resolving the contradiction between overall strength and weight reduction.
Solution Approach 2:
The frame exhibits local quality variations through non-uniform thickness distribution. The peripheral section and specific reinforcement zones have greater thickness for enhanced mechanical strength, while intermediate sections have reduced thickness to minimize weight. This local differentiation enables the frame to optimize the balance between strength and weight by concentrating material only where mechanically necessary.
2Strength
If the frame thickness is increased to protect the transparent panel, then the mechanical resistance is improved, but the weight and manufacturing cost increase
Solution Approach 1:
The frame thickness is segmented into multiple levels: a baseline thickness for general structural support, and increased thickness at critical locations (periphery, hinge connections, locking mechanism areas). This segmentation eliminates the need for uniform thick framing throughout, reducing overall weight while maintaining mechanical resistance at stress-critical points.
Solution Approach 2:
The frame employs local quality enhancement by varying thickness according to mechanical stress distribution. Thicker sections are strategically placed at the periphery and reinforcement zones where highest stresses occur, while thinner sections are used in low-stress areas. This localized thickening provides necessary mechanical resistance without the penalty of uniformly increasing frame weight.
3Strength
If reinforcement elements are added at mechanically stressed locations, then the mechanical strength is improved, but the device complexity increases
Solution Approach 1:
The reinforcement elements are merged with the frame to form an integrated, substantially one-piece structure. The reinforcement zones are incorporated directly into the frame during manufacturing rather than being separate attached components. This merging reduces assembly complexity and the number of parts while still providing the necessary mechanical strength at stressed locations.
Solution Approach 2:
The frame serves multiple functions simultaneously: it provides overall structural support, protects the transparent panel, and incorporates built-in reinforcement zones for high-stress areas. The peripheral and reinforcement sections perform both structural and protective functions, eliminating the need for separate reinforcement components and reducing overall device complexity.
Data Source
Figure 1~4
AI summary
The invention relates to a tailgate (1) for a motor vehicle (2), intended to be mounted on the upper part of the body (3) of the vehicle (2), the tailgate (1) comprising a support frame (13), a transparent panel (14) rigidly connected to the frame (13), hinge-forming elements (15, 15'), and means for actuating the opening and closing of the tailgate. According to the invention, the frame (13) has a generally U-shaped cross-section disposed between an upper part (17) and a lower part (18) of the transparent panel (14).