AU2022215151A1 - A composite tailgate assembly for a vehicle and a method therof - Google Patents

Abstract

The embodiments herein achieve a lightweight composite tailgate assembly suitable for use in motor vehicles and the like. Further, the embodiments herein achieve the lightweight composite tailgate assembly that is corrosion resistant and having substantially reduced tooling costs as compared to conventional steel tailgates. Furthermore, the embodiments herein achieve the lightweight composite tailgate assembly which lowers the overall weight of the vehicle and improves the styling flexibility. The embodiments herein further achieve the lightweight composite tailgate assembly which is made-up of composite plastic. Additionally, the embodiments herein achieve a method of forming a lightweight composite tailgate assembly. Fig. 1 1/3 100 104a 112 114 124 116 122 126 118 104b 106 FIG. 1

Description

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FIG. 1

"A COMPOSITE TAILGATE ASSEMBLY FOR A VEHICLE AND A METHOD THEROF" CROSS REFERENCE TO RELATED APPLICATION

This application is based on and derives the benefit of Indian Application 202141035692 filed on 0 6 th August 2021, the contents of which are incorporated herein by reference.

TECHNICAL FIELD

[001] The embodiments herein generally relate to doors and closures in motor vehicles, more particularly, relates to a light weight composite tailgate assembly suitable for use in motor vehicles and the like.

BACKGROUND

[002] A conventional tailgate for a motor vehicle is formed from a number of steel sheets that are stamped and welded together. A steel reinforcement member is welded to the sheets to provide strength and rigidity to the tailgate. These conventional tailgates have, however, certain disadvantages. For instance, the tooling required to manufacture the tailgates from steel is expensive. Further, the steel panels are subjected to moisture, road salt, and other chemical agents in the environment which are corrosive to steel and eventually detract from its structural integrity and appearance. In addition, the use of steel results in a heavy tailgate that is, for some individuals, difficult to open and close. Such a heavy tailgate also adds to the overall weight of the motor vehicle, which unnecessarily increases fuel consumption. Further, there are also styling restrictions with traditional sheet metal components.

[003] Consequently, plastic panels have been incorporated into the conventional tailgates in an attempt to reduce the weight thereof. A conventional art discloses a tailgate assembly including a metal sheet deformed into an inner panel, an outer panel, a top panel, a bottom panel, and side panels. A plastic reinforcing module is disposed between the inner and outer panels, and is affixed to the inner structural panel by a fastener. The reinforcing module includes a plurality of legs extending in various directions in order to add stiffness, strength, and dent resistance to the tailgate assembly. However, tailgates formed of plastics often lead to problems of insufficient rigidity due to the materials used therein. Also, thermoplastic composite type materials used for lift-gate applications have difficulty in meeting customer performance specifications.

[004] Accordingly, there is a consistent need to provide a lightweight, strong, durable tailgate panel for vehicles that has minimal impact upon vehicle cost. It is also desirable to reduce tailgate weight in order to improve fuel efficiency of the vehicle.

[005] Therefore, there exists a need for a composite tailgate assembly, which obviates the aforementioned drawbacks.

OBJECTS

[006] The principal object of an embodiment herein is to provide a composite tailgate assembly suitable for use in motor vehicles and the like.

[007] Another object of an embodiment herein is to provide the composite tailgate assembly which is light in weight, corrosion resistant and having substantially reduced tooling costs as compared to conventional steel tailgates.

[008] Another object of an embodiment herein is to provide the lightweight composite tailgate assembly which lowers overall weight of the vehicle and improves styling flexibility.

[009] Yet another object of an embodiment herein is to provide the lightweight composite tailgate assembly which made-up of composite plastic.

[0010] Yet another object of an embodiment herein is to provide a method of forming a composite tailgate assembly.

[0011] These and other objects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF DRAWINGS

[0012] The embodiments of the invention are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:

[0013] Fig. 1 depicts a front view of a composite tailgate assembly, according to embodiments as disclosed herein;

[0014] FIG. 2 depicts an exploded view of the composite tailgate assembly, according to embodiments as disclosed herein; and

[0015] FIG. 3 depicts a flowchart depicting a method of forming a lightweight composite tailgate assembly, according to embodiments as disclosed herein.

DETAILED DESCRIPTION

[0016] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

[0017] The embodiments herein achieve a composite tailgate assembly suitable for use in motor vehicles and the like. Further, the embodiments herein achieve the composite tailgate assembly which is light in weight, corrosion resistant and having substantially reduced tooling costs as compared to conventional steel tailgates. Furthermore, the embodiments herein achieve the lightweight composite tailgate assembly which lowers the overall weight of the vehicle and improves the styling flexibility. The embodiments herein further achieve the lightweight composite tailgate assembly which is made-up of composite plastic. Additionally, the embodiments herein achieve a method of forming a composite tailgate assembly. Referring now to the drawing, and more particularly to Fig. 1 through 3, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.

[0018] Fig. 1 depicts a front view of a composite tailgate assembly, according to embodiments as disclosed herein. FIG. 2 depicts an exploded view of the composite tailgate assembly, according to embodiments as disclosed herein. In an embodiment, the composite tailgate assembly (100) includes an inner panel (102), an outer lower panel (106), a pair of first insert (108 and 110), a spoiler (112), at least one first cavity (114) (or pockets), a plurality of second cavities (116) (or pockets), and at least one applique portion (118). For the purpose of this description and ease of understanding, the composite tailgate assembly (100) is explained herein below with reference to a tailgate used in car or motor vehicle. However, it is also within the scope of the invention to provide the composite tailgate assembly to any similar vehicle without otherwise deterring the intended function of the composite tailgate assembly as can be deduced from the description and corresponding drawings.

[0019] The composite tailgate assembly (100) includes the inner panel (102) which forms a base structure for the tailgate (100). The inner panel (102) acts as a supporting frame for the composite tailgate assembly (100). The inner panel (102) defines a predetermined pattern or (shape) at an upper end which is adapted to receive the spoiler (112). The spoiler (112) is coupled to the inner panel (102) towards an upper end (104a) of the tailgate (100). Further, the inner panel (102) defines a predetermined pattern or (shape) at a lower end which is adapted to receive the outer panel (106). The outer panel (106) is coupled to the inner panel (102) at a lower end (104b) of the tailgate (100). In an embodiment, the spoiler (112) and the outer lower panel (106) are coupled to the inner panel (102) using PU2K (Poly Urethane 2K TOTALSEAL 6080) adhesive. However, it is also within the scope of the invention to provide any type of bonding means (or attaching means) to couple the inner panel (102) with the spoiler (112) and the outer panel (106) without otherwise deterring the intended function of the composite tailgate assembly as can be deduced from the description and corresponding drawings. In an embodiment, the inner panel (102) is made-up of PP LGF30% MB4% (polypropylene reinforced with 30% long glass fibres) material. In an embodiment, the spoiler (112) and the outer panel (106) are made up of PP EPDM TD30% (polypropylene ethylene propylene diene monomer) material. However, it is also within the scope of the invention to provide any type of material to fabricate the inner panel, the spoiler and the outer panel without otherwise deterring the intended function of the composite tailgate assembly as can be deduced from the description and corresponding drawings. Further, in an embodiment, the spoiler (112) and the outer panel (106) may be separately fabricated and affixed to the upper end (104a) and lower end (104b) of the tailgate assembly (100).

[0020] Further, the composite tailgate assembly (100) includes the pair of inserts (108 and 110) which are disposed towards the left end and right side of the composite tailgate assembly (100) respectively. Further, the pair of inserts (108 and 110) are disposed between the spoiler (112) and the outer panel (106) (as shown in FIG. 2). The pair of inserts (108 and 110) are made up of metal. In an embodiment, the pair of inserts (108 and 110) are made-up of material which is at least HSLA420 (high strength low alloy). However, it is also within the scope of the invention to provide any type of material to fabricate the first insert and the second insert without otherwise deterring the intended function of the composite tailgate assembly as can be deduced from the description and corresponding drawings.

[0021] Furthermore, the composite tailgate assembly (100) defines the at least first cavity (114) of predetermined shape. The first cavity (114) is defined towards the upper end (104a) of the tailgate (100). The first cavity (114) is defined such that the first cavity (114) is positioned below the spoiler (112). In an embodiment, the first cavity (114) is defined in the inner panel (102) to mount at least one centre high mounted stop light (CHMSL).

[0022] The composite tailgate assembly (100) further includes the plurality of second cavities (116) of predetermined shape which are defined towards mid-section (126) of the composite tailgate assembly (100). The plurality of second cavities (116) are formed in left and right side of the tailgate assembly (100). In an embodiment, the plurality of second pockets (116) are defined in the tailgate (100) to receive corresponding plurality of taillight units (122) of the vehicle. In an embodiment, the taillight units (122) may be fabricated separately and received in the plurality of second pockets (116) of the composite tailgate assembly (100).

[0023] Furthermore, the composite tailgate assembly (100) includes the at least one applique portion (118) which is defined in the outer panel (106) and below the mid-section (126) of the tailgate (100). In an embodiment, the at least one applique portion (118) is configured to receive at least one number board (not shown) (or number plate) (not shown) and a plurality of fasteners (not shown). The name board (not shown) (not shown) is affixed to the applique portion (118) using the plurality of fasteners (not shown).

[0024] Further, the composite tailgate assembly (100) includes a first opening (124) which is defined between the upper end (104a) and the mid-section (126) of the composite tailgate assembly (100). In an embodiment, the first opening (124) of the tailgate assembly (100) is configured to receive at least one transparent glass. The first opening with the transparent glass is mainly configured to allow light of pass into an interior or cabin of the vehicle.

[0025] Further, the composite tailgate assembly includes (100) a plurality of ribs (or a plurality of reinforcement members) (128) which are disposed at predetermined locations of the tailgate assembly (100) to provide strength and rigidity to the tailgate assembly (100).

[0026] The technical advantages provided by the embodiments herein include reduced tooling costs as compared with conventional steel tailgates, lightweight, lowers the overall weight of the vehicle, and improves styling flexibility.

[0027] FIG. 3 depicts a flowchart depicting a method of forming a lightweight composite tailgate assembly, according to embodiments as disclosed herein. In an embodiment, the method (300) includes providing an inner panel (102) having a predetermined shape and size (at step 302). Further, the method (300) includes mounting a pair of inserts (108 and 110) on said inner panel (102), said pair of inserts (108 and 110) disposed towards a left side and a right side of said inner panel (102) (at step 304). Furthermore, the method (300) includes coupling an outer panel (106) to said inner panel (102) at a lower end (104b) of said inner panel (102) (at step 306). Additionally, the method (300) includes attaching a spoiler (112) towards an upper end (104a) of said inner panel (102) (at step 308).

[0028] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.

Claims (13)

STATEMENT OF CLAIMS We claim,

1. A composite tailgate assembly (100) for a vehicle, comprising: an inner panel (102); an outer panel (106) coupled to said inner panel (102) at a lower end (104b) of said inner panel (102); a spoiler (112) coupled towards an upper end (104a) of said inner panel (102); and a pair of inserts (108 and 110) connected to said inner panel (102), said pair of inserts (108 and 110) disposed towards a left side and a right side of said inner panel (102).

2. The composite tailgate assembly (100) as claimed in claim 1, wherein said inner panel (102) defines at least one first cavity (114) of predetermined dimension towards said upper end (104a) of said inner panel (102).

3. The composite tailgate assembly (100) as claimed in claim 1, wherein said inner panel (102) defines a plurality of second cavities (116) which are disposed towards a mid-section (126) of said tailgate assembly (100).

4. The composite tailgate assembly (100) as claimed in claim 1, wherein said outer panel (106) defines at least one applique portion (118) which is positioned below said mid-section (126) of the tailgate (100), said applique portion (118) is configured to receive at least one board (not shown) and a plurality of fasteners to attach said board (not shown) to said outer panel (106).

5. The composite tailgate assembly (100) as claimed in claim 1, wherein said composite tailgate assembly (100) includes a first opening (124) of predetermined dimensions defined between said upper end (104a) and said mid-section (126) of said tailgate assembly (100), said first opening (124) is configured to receive at least one transparent glass.

6. The composite tailgate assembly (100) as claimed in claim 1, wherein said outer lower panel (106) and said spoiler (112) are coupled to said inner panel (102) using an adhesive means, said adhesive means is at least PU2K adhesive.

7. The composite tailgate assembly (100) as claimed in claim 1, wherein said inner panel (102) is made-up of composite plastic material, said composite plastic material is at least PP LGF % MB 4% material.

8. The composite tailgate assembly (100) as claimed in claim 1, wherein said outer lower panel (106) and said spoiler (112) are made-up of composite plastic material, said composite plastic material is at least PP EPDM TD30% material

9. The composite tailgate assembly (100) as claimed in claim 1, wherein said first insert (108) and said second insert (110) is fabricated using a metal, said metal is at least HSLA420 material

10. The composite tail gate (100) as claimed in claim 1, wherein said inner panel (102) includes a plurality of reinforcements members (128) are disposed within said inner panel (102) at predetermined positions.

11. The composite tailgate assembly (100) as claimed in claim 2, wherein said first cavity (114) is defined in said inner panel (102) to mount at least one stop light such as a centre high mounted stop light.

12. The composite tailgate assembly (100) as claimed in claim 1, wherein each of said plurality of second cavity (116) is adapted to receive corresponding taillight units (122).

13. A method (300) of forming a lightweight composite tailgate assembly, comprising: providing an inner panel (102) having a predetermined shape and size; mounting a pair of inserts (108 and 110) on said inner panel (102), said pair of inserts (108 and 110) disposed towards a left side and a right side of said inner panel (102); coupling an outer panel (106) to said inner panel (102) at a lower end (104b) of said inner panel (102); and attaching a spoiler (112) towards an upper end (104a) of said inner panel (102).