Multidisciplinary tailgate guide bumper design for electric vehicles: Overcoming rattle, separation noise and closure effort trade-offs

초록

A tailgate is a principal automobile component that facilitates access to the storage compartment and enhances the structural integrity of the vehicle. However, rattle noise can arise from the separation between two tailgate guide bumpers when attempting to reduce closure effort. These performance trade-offs have not been addressed due to a design gap between materials and structures. In this study, we addressed these trade-offs through a multidisciplinary design approach for materials and structures in tailgate guide bumpers. This approach provided a comprehensive understanding of how material properties, surface characteristics, and structural design affect rattle noise and closure effort. Initially, to reduce closure effort, thermoplastic vulcanizates (TPVs) were designed to achieve both low hardness and enhanced damping and wear resistance. This study found that ethylene propylene diene monomer (EPDM) contributed to enhanced damping and reduced hardness, thereby reducing closure effort. Additionally, styrene-ethylene/butylene-styrene (SEBS) prevented the degradation of wear resistance due to the low hardness of materials with a high content of EPDM. The addition of silicon was found to reduce rattle noise by decreasing surface energy, which may reduce the separation force. Next, using the optimal TPV material, the bumper shape was redesigned in order to facilitate the bending of a steel core to further reduce closure effort and rattle noise. Finally, through the analytical analysis and vehicle-level tests, the overlap dimensions between the bumpers were determined to be 2 mm to avoid rattle noise and reduce closure effort, which can be problematic at both low and high overlap dimensions. This work will offer guidance on tailgate design and introduce innovative design approaches that integrate material science with engineering design to overcome performance limitations in various industrial components. © 2025 Elsevier Ltd

키워드