Vehicle Tailgate Stiffness via V-Shaped Brace Nesting
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Solution Overview
Problem
Vehicle tailgates experience deflection when loaded with excessive weight, particularly when users stand or sit on them, due to insufficient stiffness.
Innovation Solution
The tailgate structure incorporates an upper and lower panel configuration with internal and external panels, a cavity, and V-shaped braces or gussets that are secured to each other using welds, adhesives, or fasteners, providing additional stiffness through the use of support members and reinforcement elements like beads and darts within the panels and braces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the tailgate uses a simple panel structure, then the manufacturing cost is low, but the stiffness is insufficient causing deflection under load
Solution Approach 1:
The tailgate is divided into multiple panels (outer panel, inner panel) and structural components (V-shaped braces, gussets, crossmembers) that work together to provide stiffness. The V-shaped braces are segmented into flanges and central plates, each serving specific reinforcement functions.
Solution Approach 2:
The tailgate employs a composite structure combining multiple materials including steel panels, aluminum braces, and various fasteners. The V-shaped braces and gussets create a composite framework that optimizes both stiffness and weight characteristics.
2Stability of the object's composition
If the tailgate structure is reinforced with additional braces and panels, then the deflection is reduced, but the manufacturing complexity increases
Solution Approach 1:
The V-shaped braces, gussets, and crossmembers are pre-formed and pre-positioned within the cavity before final assembly. This preliminary preparation of structural components simplifies the overall manufacturing process by allowing modular assembly rather than complex in-situ fabrication.
Solution Approach 2:
The V-shaped braces and gussets are nested within the cavity formed by the panels, with the central plate of the V-brace positioned within the space defined by the outer and inner panels. This nested arrangement maximizes structural efficiency while minimizing external dimensions.
3Strength
If the tailgate uses thicker panels and more material, then the load-bearing capacity increases, but the weight of the tailgate increases
Solution Approach 1:
Rather than uniformly thickening all panels, the reinforcement is applied locally where needed - V-shaped braces at critical stress points, gussets at corner joints, and crossmembers in specific regions. This localized reinforcement provides maximum strength with minimum additional weight.
Solution Approach 2:
The V-shaped braces introduce curved geometric forms that efficiently distribute loads through their angular geometry. The curved and angular shapes of the braces provide structural strength while using less material than straight rigid beams would require.
Data Source
AI summary
A vehicle tailgate includes an upper panel, lower panel, internal panel, external panel and brace. The upper and lower panels are spaced apart relative to each other. The internal and external panels are each secured to the upper and lower panels. A cavity is defined between the upper, lower, internal, and external panels. The brace is disposed within the cavity. The brace includes first and second flanges extending outward from a central plate. The first and second flanges are secured to the internal panel while the central plate is secured to the external panel.