Conductor Connecting Structure for Wire Harness Reliability
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Solution Overview
Problem
Conventional conductor connecting structures in wire harnesses face challenges in achieving strong connections that can resist detachment forces between different types of conductors, particularly between single-core and twisted wires, leading to reliability issues.
Innovation Solution
A conductor connecting structure where one conductor is a pipe member with a barrelled shape enclosing the end of another conductor, and a tubular member is crimped onto their overlapping portion, enhancing the contact area and joint strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If ultrasonic welding is used to connect single-core wire and twisted wire, then the connection process is simple, but the joint strength is insufficient to resist detachment forces
Solution Approach 1:
The patent implements a nested structure where the pipe member is inserted into the barrel portion, and the tubular member is crimped over the overlapping portion. This nested configuration creates multiple layers of mechanical interlocking, significantly enhancing joint strength while maintaining connection simplicity through standardized assembly steps.
Solution Approach 2:
The connection structure combines different conductor types (single-core wire and twisted wire) with different structural components (pipe member, barrel portion, tubular member) to create a composite assembly. This composite approach leverages the strengths of each component to achieve both ease of manufacture and high joint strength.
2Length of moving object
If single-core wires are used in non-flexible sections to reduce diameter, then the wire harness diameter is reduced, but the connection reliability between different conductor types deteriorates
Solution Approach 1:
The patent transitions from a simple linear connection to a multi-dimensional structure by adding the barrel portion that encloses the pipe member and the tubular member that crimped over the overlapping portion. This dimensional expansion creates a robust three-dimensional connection that maintains reliability while accommodating different conductor types in a compact arrangement.
3Area of stationary object
If a barrel portion with barreled shape is used to enclose the end portion of another conductor, then the contact area increases, but the device complexity increases
Solution Approach 1:
The connection structure is segmented into distinct functional components: the pipe member, the barrel portion with barreled shape, and the tubular member. This segmentation allows each component to be optimized independently for its specific function while maintaining overall simplicity through modular assembly.
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
The configuration significantly improves the reliability of connections by providing a strong joint that resists detachment forces and prevents the joint from catching on other components, while maintaining flexibility and preventing thermal deformation.
Implementation Method 1
a tubular member encloses, and is crimped onto, an overlapping portion where the first conductor and the second conductor overlap each other
Data Source
AI summary
A conductor connecting structure and a wire harness are able to improve connection reliability. An end portion of a first conductor and an end portion of a second conductor overlap each other in a radial direction, and a tubular member encloses, and is crimped onto, an overlapping portion where the first conductor and the second conductor overlap each other. With this configuration, it is possible to make a joint strong enough to resist a force applied in a direction in which the end portion of the first conductor and the end portion of the second conductor are detached from each other, and therefore it is possible to improve the reliability of connection between the first conductor and the second conductor.