Hybrid Composite Tailgate Reinforcement Around the Window Opening
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Solution Overview
Problem
Current automotive tailgate designs face challenges in achieving significant weight reduction while maintaining mechanical properties and aesthetics, with existing lightweight solutions being costly and requiring metal inserts for thermal and mechanical expansion.
Innovation Solution
A hybrid tailgate with a thermoplastic inner structure and continuous fiber reinforced composite reinforcement parts, forming a continuous load path around the tailgate window opening, which replaces metal inserts and integrates ribbing structures for enhanced reinforcement without additional cladding, using injection molding or adhesion for connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If aluminum is used for tailgate to maintain mechanical properties, then strength is improved, but weight increases and cost increases
Solution Approach 1:
The patent uses a composite structure combining thermoplastic polyolefin (TPO) inner structure with aluminum composite panels. The TPO provides flexibility and weight reduction while the aluminum composite panels provide structural strength and stiffness, achieving both weight reduction and maintained mechanical properties through material composition
2Strength
If aluminum is used for tailgate to maintain mechanical properties, then strength is improved, but cost increases
Solution Approach 1:
The patent merges the TPO inner structure with aluminum composite panels into a single integrated tailgate assembly. This combination allows the use of cost-effective TPO for the main structure while applying aluminum panels only where structural strength is needed, reducing overall material costs compared to full aluminum construction
3Weight of moving object
If plastic tailgate is used to reduce weight and cost, then weight is reduced and cost is reduced, but mechanical strength decreases
Solution Approach 1:
The patent employs a composite construction where TPO forms the lightweight base structure and aluminum composite panels are integrated to provide enhanced mechanical strength. This composite approach allows the tailgate to be lighter than full aluminum designs while maintaining adequate strength through the synergistic combination of materials
4Strength
If metal inserts are used in plastic tailgate to meet mechanical requirements, then strength is improved, but device complexity increases
Solution Approach 1:
The patent integrates aluminum composite panels directly with the TPO inner structure through bonding or mechanical attachment, merging two materials into a unified structural system. This integration eliminates the need for separate metal inserts and additional fastening components, reducing device complexity while maintaining the strength benefits of aluminum
Data Source
AI summary
The invention relates to a hybrid tailgate for a vehicle, comprising a thermoplastic inner structure forming the carrier frame of the tailgate, and at least one composite reinforcement part to reinforce the carrier frame, wherein the composite reinforcement part is connected to the thermoplastic inner structure at a first surface, wherein the composite reinforcement part forms a continuous load path in the inner structure enclosing a tailgate window opening for a window glazing part of the tailgate. Furthermore, the invention relates to a vehicle comprising such a hybrid tailgate. Moreover, the invention relates to a method of manufacturing such a hybrid tailgate, the method comprising forming a composite laminate part into an insert; placing the insert in an injection molding tool; and over-molding the insert with polymer resin.