Branching Wire Harness Layout for Waterproof LED Lighting
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Solution Overview
Problem
Conventional lighting systems restrict the arrangement of straight tube LED lamps due to their direct connection with waterproof sockets, limiting flexibility in placement.
Innovation Solution
A wire harness system comprising a trunk line, branching units, and branch lines with insulated conductor connections, allowing for flexible arrangement of lighting fixtures through branching units covered by insulating materials, and using heat shrink tubes and adhesive for enhanced waterproofing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If straight tube LED lamps are directly connected to waterproof sockets on connecting wires, then the connection structure is simple, but the arrangement flexibility of lighting fixtures is restricted
Solution Approach 1:
The wire harness is segmented into a trunk line and multiple branch lines with branching units. This segmentation allows lighting fixtures to be connected at different locations along the branch lines, providing flexible arrangement while maintaining a structured connection system. The branching units serve as independent connection points that can be positioned according to spatial requirements.
Solution Approach 2:
The patent transitions from a one-dimensional linear connection (direct connection to waterproof sockets on a single wire) to a two-dimensional tree-like structure with trunk and branch lines. This dimensional change enables lighting fixtures to be arranged in multiple directions and positions, significantly improving arrangement flexibility while maintaining organized connections.
2Adaptability or versatility
If branching units with conductor connections are provided, then arrangement freedom is improved, but waterproof performance may be compromised
Solution Approach 1:
The branching unit employs a nested structure where the conductor connection portion is covered by an insulating material layer, which is in turn covered by a heat shrink tube. This nested arrangement protects the electrical connections from water ingress while maintaining the functional branching structure for flexible lighting fixture placement.
Solution Approach 2:
The insulating material and heat shrink tube act as intermediary protective layers between the conductor connection portion and the external environment. These intermediaries provide waterproof protection without interfering with the electrical connection function, allowing both arrangement freedom and waterproof performance to coexist.
3Adaptability or versatility
If multiple branching units are provided for flexible arrangement, then the number of connection points increases, but the manufacturing complexity increases
Solution Approach 1:
The branching unit is designed as a universal module that can be repeatedly applied at multiple locations along the trunk line. Each branching unit serves the same function of creating a connection point with waterproof protection, allowing standardized manufacturing processes to be used across multiple connection points, thereby reducing overall manufacturing complexity despite the increased number of connections.
Solution Approach 2:
The insulating material is pre-formed and the heat shrink tube is pre-positioned on the conductor connection portion before final assembly. This preliminary preparation of protective components simplifies the manufacturing process by separating the connection-making step from the waterproofing step, allowing each to be optimized independently.
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
Improves the degree of freedom in arranging lighting fixtures while maintaining high waterproof performance, enabling flexible placement and efficient power distribution.
Implementation Method 1
the tubular body comprises a heat shrink tube
Implementation Method 2
an adhesive that fills a gap between an inner surface of the heat shrink tube and the conductor connection portion and surroundings thereof
Data Source
AI summary
A wire harness includes a trunk line extending from an upstream side to a downstream side, a plurality of branching units respectively provided at each of a plurality of branching points on the trunk line, and a plurality of branch lines branching out from the plurality of branching units, wherein the trunk line includes a trunk conductor, wherein the branch line includes a branch conductor, and wherein the branching unit includes a conductor connection portion that electrically connects the trunk conductor on the upstream side to the trunk conductor on the downstream side and to the branch conductor, and a cover portion including an insulating material that covers the conductor connection portion and surroundings thereof.