The tailgate, as the rearmost vehicle opening, plays a pivotal role in defining the rear aesthetic theme while ensuring structural durability and maximizing luggage space. Contemporary automotive design trends highlight an increasing demand for Full width tailgate-mounted tail lamp configurations, which deliver a bold and dynamic visual appeal. Enhanced by animated lighting features, these designs cater to the preferences of Gen Z customers, becoming a decisive factor in purchasing decisions.
However, integrating these complex tail lamp structures introduces significant engineering challenges, including increased X-dimension lamp volume, thereby providing reduced design space, and intricate mounting schemes constrained by panel stamping limitations. These factors necessitate the development of innovative joinery strategies and structural definitions to maintain durability targets, including achieving 25,000–30,000 slam cycles without failure, while preserving luggage space.
This paper presents a comprehensive design and engineering approach aimed at enhancing the modal performance of automotive tailgate systems, with a particular focus on configurations incorporating full width taillamps. The study addresses key structural challenges associated with maintaining stiffness and durability while accommodating complex styling and packaging constraints. By optimizing outer panel joinery, refining mounting strategies, and redefining inner structural reinforcements, the proposed methodology achieves significant improvements in dynamic stiffness characteristics. Experimental and simulation-based evaluations demonstrate a 12% increase in modal stiffness for conventional tailgate architectures and a 45% improvement in coupe-type liftgate configurations. The findings offer valuable insights into the co-development of structural and styling elements in modern tailgate systems, contributing to improved vehicle performance, NVH behavior, and customer satisfaction.