Tonneau Cover Wire Routing Across Folding Panel Hinges
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Solution Overview
Problem
Foldable tonneau covers with electrical components face issues with cable damage and obstruction of cargo space during folding and unfolding, as cables are prone to stretching, pinching, and hanging into the truck bed.
Innovation Solution
A wire management system is introduced, featuring a junction box with an electrical connector, an electrical wire attached to the connector, and a mechanism to manage slack, ensuring the wire remains taut over the panel interfaces during folding and unfolding, preventing damage and obstruction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical cables connect tonneau cover panels through hinged interfaces, then electrical components can be powered across panels, but the cables are overly stretched and strained or twisted and pinched during folding and unfolding
Solution Approach 1:
The patent applies dynamics by making the cable routing adaptable to the changing geometry of the tonneau cover during folding and unfolding. The cables are routed through channels that allow them to flex and change position dynamically, preventing stretching and pinching while maintaining electrical connectivity across moving panel interfaces
Solution Approach 2:
The patent uses cable management channels and guides as intermediary structures between the electrical components and the moving panels. These intermediaries protect the cables from direct contact with hinge mechanisms and cargo, while providing a controlled path that accommodates panel movement without damaging the cables
2Ease of operation
If electrical cables are routed along the undersurface of panels into the cargo box, then electrical components can be connected, but the cables may interfere with or be damaged by cargo in the bed of the truck
Solution Approach 1:
The patent introduces cable management channels and protective guides as intermediary structures that separate the electrical cables from the cargo space. These intermediaries create a dedicated pathway for cables along the panel edges and undersurfaces, preventing direct contact with cargo while maintaining easy cable routing and connection
Solution Approach 2:
The patent routes cables along the vertical edges and contours of the tonneau cover panels rather than allowing them to hang freely in the horizontal cargo space. This dimensional change in cable positioning removes them from the harmful cargo environment while preserving electrical connectivity
3Adaptability or versatility
If tonneau cover panels are folded onto one another, then access to or uncover a portion of the bed, but the cables hanging from the undersurface of panels obstruct the cargo box
Solution Approach 1:
The patent implements dynamic cable management where the cable routing adapts to the folded position of the tonneau cover panels. When panels are folded to provide bed access, the cables are contained within channels that follow the panel contours, preventing them from hanging down and obstructing the cargo box while maintaining full adaptability of the cover system
Data Source
AI summary
A foldable panel assembly (e.g., foldable tonneau cover) having first and second panels, the second panel being rotatably attached to the first panel about an axis of rotation. A wire management system is provided including a junction box disposed with the first panel and having an electrical connector. An electrical wire is attached to the electrical connector and extends from the junction box over an interface between the first and second panels. In the extended position, the electrical wire has an amount of slack sufficient to allow the electrical wire to move relative to one or both panels. In the folded position, the amount of slack in the electrical wire is reduced relative to the extended position and the electrical wire is taut over the interface. This configuration permits the panels to be folded and unfolded without pinching or straining the electrical wire during said folding and unfolding.