Bonder Cap Accommodating Structure for Wire Harness

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Solution Overview

Problem

The increasing number of electrical wires in vehicles due to electronic components leads to cumbersome attachment work when using multiple bonder caps, as each cap needs to be individually attached to an electrical connection box.

Innovation Solution

A bonder cap accommodating structure that includes a tying member to tie multiple bonder caps together and an accommodating part within the electrical connection box, allowing the tied caps to be collectively inserted and secured, reducing the complexity and time of attachment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple bonder caps are individually attached to the electrical connection box, then each cap is securely fixed, but the attachment work becomes burdensome and time-consuming

Engineering Contradiction:

Improvesecure fixation of bonder capsVSAvoidattachment work

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

Multiple separate bonder caps are merged into a single integrated unit by being collectively wrapped with one bonder cap. This allows multiple caps to be attached to the electrical connection box as one unit, significantly reducing the attachment work while maintaining secure fixation of each individual cap.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If multiple bonder caps are used to cover conductor parts, then all conductor connections are protected, but the number of components increases making attachment burdensome

Engineering Contradiction:

Improveprotection of conductor partsVSAvoidnumber of bonder caps

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Multiple bonder caps that would normally be separate components are merged into one integrated structure by wrapping them collectively with a single bonder cap. This reduces the number of separate components from multiple individual caps to one unified assembly, simplifying the overall device complexity while maintaining protection of all conductor parts.

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If multiple bonder caps are individually accommodated in the electrical connection box, then each cap is properly positioned, but the attachment process becomes complex and time-consuming

Engineering Contradiction:

Improvepositioning of bonder capsVSAvoidattachment process

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

Multiple bonder caps are preliminarily assembled into a unified structure by collectively wrapping them with one bonder cap before being placed into the electrical connection box. This preliminary grouping action allows the caps to be positioned accurately as a single unit, maintaining manufacturing precision while significantly reducing the time required for the attachment process.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS10819045B2Bonder cap accommodating structure, electrical connection box, and wire harness

Publication Date: 2020.10.27 YAZAKI CORP

AI summary

A bonder cap includes a plurality of electrical wire bundles each having conductor parts in a plurality of electrical wires therein connected together and covered by a bonder cap; a tying member configured to tie the bonder caps together by being integrally wound around the bonder caps that are included in the electrical wire bundles; and an accommodating part into which the bonder caps that have been tied together by the tying member are inserted and in which the bonder caps are integrally accommodated.