Bridging Simulation and Reality: A New Validation Approach for SUV Tailgate Weather-Strip Sealing Performance

Weather-strip sealing performance is critical in modern SUVs for preventing the intrusion of noise, dust, and water, directly affecting cabin comfort and NVH quality. Traditionally, experimental validation of sealing efficiency has been conducted using flat or straight JIG setups, which do not accurately represent the complex contact conditions found in actual vehicle assemblies. Components such as tailgates, doors, hoods, roofs, and bumpers typically interface with the weather-strip through curved, angled, or non-uniform surfaces, resulting in a mismatch between lab-based results and real-world performance. This study addresses the limitations of conventional flat JIG testing by proposing a more vehicle-integrated validation methodology that mirrors actual contact geometries and sealing behavior. The objective is to reduce the disparity between laboratory results and in-vehicle sealing performance, enabling more reliable design decisions and early-stage NVH optimization. The approach integrates two parallel workflows. In the numerical domain, finite element analysis (FEA) is conducted using both flat JIG CAD geometry and real vehicle CAD profiles to evaluate sealing pressure distribution under realistic compression loads. In the experimental domain, flat JIG physical tests are correlated with FEA predictions to establish a baseline. A comparative study is then performed to assess differences in sealing performance between flat JIG and vehicle-specific geometries. Results indicate that the proposed method provides a more accurate representation of contact behavior and sealing efficiency, validating its use for future development. This work recommends adopting vehicle-profile-based validation as a standard practice for weather-strip design and qualification.