Connector-Segmented Wiring for Extra-Thin Wire Tensile Protection

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Solution Overview

Problem

The application of extra-thin electrical wires with small conductor cross-sectional areas is limited by their tensile strength and impact resistance, restricting their use in various positions where higher strength is required.

Innovation Solution

A wiring system that incorporates extra-thin electrical wires with a conductor cross-sectional area of 0.13 sq or less, connected through a network of main wire-side and terminal-side connectors, allowing the wires to be used in a wider range of applications by distributing tensile forces across multiple circuits, thereby enhancing their strength and durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If extra-thin electrical wires with small conductor cross-sectional area are used, then cost and weight are reduced, but tensile strength and impact strength are insufficient

Engineering Contradiction:

Improveweight of wiring systemVSAvoidtensile strength of electrical wire

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The wiring system is divided into main wire-side circuits and terminal-side circuits connected through connectors. The extra-thin electrical wires are used in terminal-side circuits where they can be supported by the connector structure, while main wire-side circuits use thicker wires for strength. This segmentation allows extra-thin wires to be used without compromising overall system strength.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different conductor cross-sectional areas are used in different parts of the wiring system. Extra-thin wires (0.13 sq or less) are used in terminal-side circuits where weight reduction is critical and mechanical stress is minimized by the connector support. Thicker wires are used in main wire-side circuits that require higher tensile strength. This local differentiation optimizes both weight and strength where needed.

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If extra-thin electrical wires with small conductor cross-sectional area are used, then cost is reduced, but tensile strength and impact strength are insufficient

Engineering Contradiction:

Improvecost of wiring systemVSAvoidimpact strength of electrical wire

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The wiring system separates terminal-side circuits using extra-thin cost-effective wires from main wire-side circuits using thicker wires. The connector architecture provides mechanical support that compensates for the lower impact strength of extra-thin wires, allowing cost reduction without sacrificing overall system durability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Extra-thin electrical wires with conductor cross-sectional area of 0.13 sq or less are used in terminal-side circuits where cost reduction is prioritized and mechanical stress is managed by connector support. This localized use of thinner wires reduces material cost while maintaining adequate impact strength through proper structural support at connection points.

Inventive Principle:

Principle #3Local quality

3Weight of moving object

If extra-thin electrical wires are used in positions requiring high strength, then weight and cost are reduced, but reliability under tensile load is compromised

Engineering Contradiction:

Improveweight of electrical wireVSAvoidreliability of electrical wire under tensile load

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The wiring system divides circuits into terminal-side and main wire-side portions. Extra-thin wires are used in terminal-side circuits where they are protected by connector structures from tensile loads. Main wire-side circuits use thicker wires that can handle tensile stresses, ensuring reliability where mechanical strength is required.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Extra-thin electrical wires are used in terminal-side circuits where weight reduction is critical and tensile stress is minimized through connector support. The connector architecture provides mechanical reinforcement at connection points, allowing reliable use of extra-thin wires in positions where they are protected from excessive tensile loads.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20250006401A1Wiring system

Publication Date: 2025.01.02 SUMITOMO WIRING SYSTEMS LTD

AI summary

A wiring system includes: a main wire-side wiring member including a plurality of main wire-side circuits and a plurality of main wire-side connectors, the plurality of main wire-side circuits bundled in a form with a plurality of connection ends; and a terminal-side wiring member including a terminal-side connector connected to any one of the plurality of main wire-side connectors and a terminal-side circuit connected to the terminal-side connector, wherein the plurality of main wire-side connectors include an extra-thin electrical wire connector, the plurality of main wire-side circuits include a plurality of extra-thin electrical wire connector connection circuits connected to the extra-thin electrical wire connector, and the plurality of extra-thin electrical wire connector connection circuits include an extra-thin electrical wire having a conductor cross-sectional area of 0.13 sq or less as an extra-thinnest electrical wire having a smallest conductor cross-sectional area.