Conductor Clip and Cover Assembly for High-Density Wire Routing
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Solution Overview
Problem
In environments with numerous wires, such as solar power generation settings, wires often become entangled or disorganized, leading to damage, reduced performance, and aesthetic issues, as well as potential electrical hazards due to contact with surfaces and environmental factors.
Innovation Solution
A wire routing assembly comprising a wire clip with a body and wire holders, and a detachable cover that can be slidably mounted to retain wires, keeping them organized and protected from environmental factors by being securely fastened to a support structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If wires are left unorganized in environments with numerous wires, then installation is simpler and faster, but wires become entangled and disorganized leading to damage and electrical hazards
Solution Approach 1:
The wire management system is divided into modular components: individual wire holders that can be separately attached to the body, and detachable covers that can be independently mounted. This segmentation allows for flexible installation where components can be assembled in stages, making the overall system easier to install while maintaining complete wire organization and protection capabilities.
Solution Approach 2:
The wire holders are pre-configured with cavities and openings designed to receive and organize wires before the covers are attached. This preliminary arrangement ensures wires are properly positioned and protected from the start, preventing entanglement and damage during installation while maintaining ease of assembly through the modular design.
2Reliability
If wires are protected from environmental factors, then wire durability and performance are maintained, but the assembly becomes more complex with additional cover components
Solution Approach 1:
The cover is designed to nest over the wire holders and body, with the lip receiving onto the body structure. This nested configuration provides complete environmental protection for the wires within the holders while using a single integrated cover component rather than multiple separate protective elements, thereby reducing overall assembly complexity.
Solution Approach 2:
The cover serves multiple functions simultaneously: it protects wires from environmental factors, maintains organizational structure, and provides a unified external appearance. The wire holders also serve dual purposes by both organizing wires and providing mounting surfaces for the covers, reducing the need for additional separate components.
3Object-affected harmful factors
If detachable covers are used to protect wires, then wires are protected from damage and electrical hazards, but installation and maintenance require more steps
Solution Approach 1:
The cover is designed with detachable mounting via lips that receive onto the body, allowing the cover to be easily attached and removed as needed. This dynamic, reversible connection provides full environmental protection when assembled while enabling quick installation and maintenance access without permanent fixation, thereby maintaining ease of operation.
Solution Approach 2:
The lip structure acts as an intermediary mechanism between the cover and body, providing a simple interface for detachable mounting. This intermediary feature enables easy attachment and removal of the protective cover while ensuring proper alignment and secure fitting, balancing protection capabilities with installation simplicity.
4Reliability
If multiple wire holders are used to organize numerous wires, then wire organization and protection are improved, but the device becomes more complex and harder to assemble
Solution Approach 1:
Multiple wire holders are merged into a single integrated body structure, where individual holders are positioned and attached to the common body. This merging approach maintains the organizational capabilities of multiple separate holders while reducing overall component count and simplifying assembly, as the holders share a common mounting structure and can be installed together as a unified assembly.
Data Source
AI summary
A wire routing assembly may include a wire clip including a body and at least one wire holder extending from the body defining a first slot; and at least one cover including a first lip and configured to mount to the at least one wire holder with the first lip being received within the first slot. The body may define a first cavity configured to be mounted to a support structure. The at least one wire holder may define at least one opening and at least one second cavity. The at least one opening and the at least one second cavity may be configured to receive at least one wire therein. The at least one cover may include a body defining a third cavity configured to receive the at least one wire holder therein, thereby retaining the at least one wire within the at least one second cavity.