Tailgate Cable Tensioner Eliminates Sag

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Solution Overview

Problem

Vehicles with tailgates often experience sagging cables due to variances in body system components, leading to an aesthetically unpleasing appearance and resulting in warranty issues.

Innovation Solution

A cable tensioner with a biasing member, such as a pair of leaf springs, that applies force to a bolt to eliminate sag in the cable, ensuring the cable is properly tensioned and aesthetically pleasing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a cable is used to secure the tailgate without a tensioner, then the system is simple and inexpensive, but the cable sags due to variances in body system components, creating an aesthetically unpleasing appearance

Engineering Contradiction:

Improvecable tensioning systemVSAvoidcable appearance

Core Design Contradiction:

Device complexityVSShape

Solution Approach 1:

A cable tensioner device is introduced as an intermediary component between the cable and the mounting points. This tensioner includes a body with a securement mechanism and a biasing member that applies force to maintain cable tension, eliminating sag while keeping the overall system relatively simple

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The biasing member (spring or leaf springs) changes the force parameter applied to the cable dynamically. When the tailgate is closed, the biasing member applies sufficient force to tension the cable and eliminate sag. When the tailgate is open, the cable can bottom out on the bolt as intended

Inventive Principle:

Principle #35Parameter changes

2Shape

If a cable tensioner with a biasing member is installed to eliminate cable sag, then the cable appearance is improved, but the device complexity and cost increase

Engineering Contradiction:

Improvecable appearanceVSAvoidcable tensioning system

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The cable tensioner is designed as an inexpensive, simple device that can be easily manufactured and installed. The use of basic components like springs or leaf springs keeps costs down while effectively solving the sagging cable appearance issue

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The biasing member (spring or leaf springs) provides automatic tensioning without requiring external power sources, control systems, or manual adjustment. The spring self-regulates the cable tension based on the tailgate position, eliminating the need for complex control mechanisms

Inventive Principle:

Principle #25Self-service

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The tensioner effectively removes slack from the cable, providing a visually appealing appearance and eliminating warranty issues related to sagging cables.

Implementation Method 1

The biasing member is a spring and preferably a pair of leaf springs

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS20250187678A1Tailgate cable pretensioner

Publication Date: 2025.06.12 FCA US LLC

AI summary

A tailgate cable tensioner having a body. A securement mechanism attaches and secures the body to a cable terminal of a cable. A biasing member applies a force on a bolt retaining the cable terminal for taking sag out of the cable.