Challenges in Power Latching Tailgate Systems

Power latching tailgate systems have become a must-have feature in modern vehicles, since they make loading and unloading cargo way easier for users. These systems use a mix of electrical parts, mechanical pieces, and sensor tech to open, close, and lock the tailgate automatically. But here’s the thing—users have pretty high hopes for them. They want the system to work smoothly every single time, react fast when they press a button or use a remote, and still hold up well against daily use—like dealing with rain, dust, or super hot or cold weather. If the system is slow to respond, gets stuck halfway, or can’t lock right, users get frustrated in no time. And that’s where the first set of problems starts for the people who make and supply parts in the auto tech industry. I’ve heard a lot of drivers complain about this kind of stuff, so it really feels like a big headache for both sides.

One major problem with power latching tailgate systems is mechanical wear and tear. The system has lots of moving parts—things like hinges, latches, and linkages—that rub against each other every time someone uses the tailgate. After a while, this constant rubbing can make parts wear out. For example, if the latch part gets worn down, it might not connect properly with the striker, which means the tailgate won’t lock securely. Dirt and bits of debris can also build up in these mechanical parts, especially if the vehicle is often driven on dusty roads or in rainy weather. This buildup makes the parts move less smoothly, and sometimes it even jams the whole system. What’s more, if the parts are made from low-quality materials, this problem gets even worse. Those parts won’t stand up to frequent use or harsh conditions, so they’ll wear out faster—and that means users have to get repairs or replacements more often. It’s like buying a cheap pair of shoes—they fall apart after just a few weeks, and you end up spending more money in the long run.

Electrical parts are what make power latching tailgate systems work, but they’re also a common source of trouble. Things like wires, sensors, and motors can stop working for all sorts of reasons. For instance, if the wires get damaged—maybe from the vehicle shaking while driving, or from water getting into the system—it can cause a short circuit. That short circuit might make the tailgate stop responding, or it could even drain the car’s battery. Sensors, which are supposed to check if there’s something in the way when the tailgate is closing, can also have issues. If a sensor is dirty or stops working right, it might not notice an obstacle, leading to the tailgate closing on something—or someone—by accident. Or it might think there’s something in the way when there’s not, so the tailgate won’t close at all. The motors that power the tailgate’s opening and closing can wear out too, especially if they’re used too much. A weak motor will make the tailgate move slowly, and eventually, it might stop working entirely. I’ve wondered before if these motors are built to handle daily use—sometimes it feels like they’re not made to last as long as the car itself.

Power latching tailgate systems don’t work on their own—they need to fit well with other parts of the vehicle, like the central locking system, keyless entry, and even the infotainment system. But getting this to work smoothly isn’t always a walk in the park. Different car models have different electrical setups and software rules, so a power latching system that works for one model might not work for another. For example, if the system can’t talk properly to the central locking system, the tailgate might not lock when the driver locks the rest of the car. Or if it doesn’t sync up with the keyless entry, the driver might not be able to open the tailgate with their key fob. Software glitches can mess this up too. A small bug in the car’s software might make the power latching system get wrong signals, leading to weird issues—like the tailgate opening by itself, or not opening when it should. It’s like trying to fit a square peg into a round hole sometimes—you have to tweak things a lot to make it work.

Another problem is trying to balance how long the system lasts with how much it weighs. Modern cars are all about being lighter to use less fuel and put out fewer emissions. So, the people who make these systems want them to be as light as possible. But making the system lighter often means using thinner materials or smaller parts, which can make it less durable. For example, a lightweight plastic latch might not be as strong as a metal one, and it could break easily if someone slams the tailgate shut by accident. On the other hand, if you use heavy-duty materials to make the system last longer, the extra weight adds to the car’s total weight—and that makes it use more fuel. It’s a real catch-22—you need the system to be tough enough to last the whole life of the car, but also light enough to fit with the car’s overall weight goals. I think this is one of the trickiest parts for designers; they really have to walk a tightrope here.

Power latching tailgate systems are out in all kinds of weather and environmental conditions, and that’s a big problem. Rain, snow, ice, and salt (the kind they put on roads in winter) can all damage the system. Water can seep into the electrical parts, causing rust or short circuits. Salt can eat away at metal parts, making them weak and more likely to break. Extreme temperatures are bad too. When it’s super hot, the plastic parts of the system might melt or get brittle. When it’s really cold, the oil in the mechanical parts can freeze, making the tailgate hard to move. Even dust and sand can get into the system, wearing down parts and causing jams. To fix this, manufacturers need to use materials that can handle bad weather, and add things like seals and covers for protection. But these extra features cost more money and add weight—so it’s another problem to deal with. I’ve seen cars with tailgates that stop working after a snowy winter, so this is definitely something that needs more attention.

Safety is the top priority for any car feature, and power latching tailgate systems are no different. There are strict safety rules that these systems have to follow to make sure they don’t hurt users. For example, the system has to stop closing if it finds an obstacle—this is to keep people from getting hurt, like a kid’s hand getting caught. It also needs a backup way to open the tailgate if the power goes out, so users aren’t stuck if the electrical system breaks. Meeting these rules isn’t easy. It means adding extra parts, like sensors to detect obstacles and manual release tools, which makes the system more complicated and expensive. What’s more, safety rules can be different in different countries. So a system that follows the rules in one place might need changes to follow the rules in another. This means more work for the people who make cars to sell all over the world. I’m glad these safety rules exist, but I can see how they make things harder for manufacturers—they have to jump through a lot of hoops.

Coming up with new ideas is key to solving the problems with power latching tailgate systems, and this is where companies with good tech skills—like Desay—can help. For example, using new materials that are both light and strong, like high-strength aluminum or tough plastic, can help balance weight and durability. Better sensor tech, like ultrasonic or infrared sensors, can make the system better at detecting obstacles and working well in different weather. Smart software can also fix integration problems—it can be programmed to work with different car systems, and updated over time to fix glitches. By putting money into research and development, companies can make power latching tailgate systems that are more reliable, last longer, and are safer. This way, they meet the needs of both the car makers and the people who drive the cars. I think if more companies focus on these new ideas, we’ll see a lot fewer problems with these tailgate systems in the future—fingers crossed, anyway.