Dual-Mode Tailgate Harness Protector Routing Under Hinge
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Solution Overview
Problem
Current methods for routing a wire harness through dual-mode tailgates with dual-action hinges require large rubber grommets, which increase the wire bundle diameter and impact surrounding parts, and are not reliable for safety-related functionality.
Innovation Solution
A harness assembly with a protector body having multiple sections and attachment members that route the wire harness under the dual-action hinge, using a slit-less corrugated tube to protect the wires and minimize impact on the vehicle body and tailgate, allowing the harness to be secured with zip ties and mounted in a limited space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a large rubber grommet is used to pass the wire harness from the vehicle body to the tailgate, then the wire harness can be routed through the dual-action hinge, but the wire bundle diameter increases and impacts surrounding parts
Solution Approach 1:
The patent extracts the wire harness routing function from the traditional rubber grommet approach and implements it through a dedicated protector assembly with a narrow-profile channel. This separates the wire routing path from the hinge mechanism, allowing the wire harness to be guided through a compact, purpose-designed structure rather than requiring a large grommet that inflates the wire bundle diameter and impacts surrounding parts.
Solution Approach 2:
The protector assembly acts as an intermediary component between the vehicle body and the tailgate, providing a dedicated pathway for the wire harness. The protector with its narrow-profile channel serves as a mediator that guides the wire harness through the dual-action hinge mechanism without requiring large clearance areas, thus resolving the contradiction between ease of routing and space constraints.
2Ease of operation
If a large rubber grommet is used to secure the wire harness, then the wire harness can be passed through the hinge, but a large body section is required to secure the grommet
Solution Approach 1:
The patent extracts the wire harness securing function from the large rubber grommet and reimplements it through the protector assembly with attachment members. The protector includes attachment members that can be secured to the vehicle body using fasteners, eliminating the need for a large body section to accommodate a large grommet while still providing secure wire harness installation.
Solution Approach 2:
The protector assembly utilizes a thin-profile structure with a narrow-profile channel that can be mounted to the vehicle body without requiring large body sections. The attachment members provide secure mounting capability through fasteners, allowing the wire harness to be installed and secured in a compact configuration that does not demand extensive body modifications.
3Ease of operation
If the wire harness is routed through a large rubber grommet, then the wire bundle can be passed through the hinge, but the routing is not reliable for safety-related functionality
Solution Approach 1:
The patent extracts the wire harness protection and routing function from the inadequate rubber grommet system and implements it through a dedicated protector assembly with a narrow-profile channel. This dedicated structure provides reliable routing for safety-related functionality by guiding the wire harness through a purpose-designed pathway that is specifically configured for this function, rather than relying on a generic grommet that compromises reliability.
Solution Approach 2:
The protector assembly serves as a reliable intermediary that ensures proper wire harness routing for safety-related functionality. The narrow-profile channel and attachment members provide a secure, dedicated pathway that maintains wire harness integrity and positioning, ensuring reliable operation of safety functions without the deficiencies of the rubber grommet approach.
Data Source
AI summary
A harness assembly for a vehicle is provided. The vehicle includes a body and a dual-mode tailgate connected to the body via a dual-action hinge The harness assembly includes a protector connected to a frame of the tailgate. The protector has a body shaped to conform to a first portion of the tailgate frame having a first contour and a second portion of the tailgate frame having a second differing contour. A portion of the protector body is configured to route a section of a tailgate harness adjacent an outboard lateral edge of the tailgate frame and past the section of the tailgate harness under a dual-action hinge.