Tailgate Hinge Wire Shield Assembly for Fatigue Protection
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Solution Overview
Problem
Existing vehicle tailgate assemblies lack effective protection for wires extending between the frame and door subassemblies, which can lead to structural fatigue and aesthetic disruption during frequent pivoting movements.
Innovation Solution
A polymer-based wire shield assembly is mounted to the hinge, rotating with the hinge and securing the wire, to maintain structural integrity and minimize aesthetic impact by using clips or fasteners, ensuring the wire remains spaced and aligned with the pivot axes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wires are exposed in the hinge area, then installation is simpler, but structural fatigue and aesthetic disruption occur during frequent pivoting
Solution Approach 1:
A wire shield assembly acts as an intermediary protective structure between the hinge components and the wire. This shield incorporates a wire channel that guides and protects the wire during hinge pivoting, preventing direct exposure to mechanical stress while maintaining proper wire routing and alignment.
Solution Approach 2:
The wire shield assembly uses a flexible or thin-walled structure that can accommodate hinge movement while maintaining wire protection. The shield's design allows it to flex or rotate with the hinge without compromising the wire's structural integrity, solving both the protection need and the movement requirement.
2Device complexity
If wires are exposed in the hinge area, then routing is simpler, but aesthetic disruption occurs during frequent pivoting
Solution Approach 1:
The wire shield assembly serves as a mediating structure that conceals the wire within its integrated channel while maintaining proper wire routing. This shield provides a clean, finished appearance that masks the complexity of wire routing within the moving hinge assembly.
3Reliability
If a wire shield assembly is added to protect the wire, then structural integrity is maintained, but device complexity increases
Solution Approach 1:
The wire shield assembly is merged with the hinge structure, integrating wire protection directly into the existing hinge components. The shield channels are formed as part of the hinge assembly structure itself, eliminating the need for separate, additional protection components and reducing overall system complexity.
Solution Approach 2:
The wire shield assembly performs multiple functions simultaneously: it protects the wire from mechanical damage, maintains proper wire alignment during pivoting, provides a finished aesthetic appearance, and integrates with the hinge structure. This multi-functionality reduces the need for separate components.
Data Source
AI summary
A vehicle assembly includes a hinge and a wire shield assembly mounted to the hinge. A method of shielding a wire can include providing a tailgate assembly that includes a door subassembly pivotably coupled to a frame subassembly. The door subassembly and the frame subassembly can be pivotable together between a tailgate closed position and a tailgate open position. The method can include pivoting the door subassembly relative to the frame subassembly to provide a cargo bed access opening; and electrically connecting the door subassembly using a wire routed through a wire shield assembly.