Direct Joining Cross-Linked Polyethylene Wire Harness Tube Waterproofing
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Solution Overview
Problem
Conventional wire waterproof structures using adhesives with cross-linked polyethylene materials are prone to softening and extrusion, leading to increased volume and cost, and compromised waterproofing performance.
Innovation Solution
A wire harness design where the cross-linked polyethylene covering materials and tubes are directly joined without adhesives, achieving a tensile shear strength of 350 kPa or more, ensuring effective waterproofing by rendering the materials compatible through heat and pressure application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an adhesive is used to join the cross-linked polyethylene covering material and the tube, then the waterproofing performance is improved, but the adhesive softens when heat is applied and is extruded to the outside of the tube
Solution Approach 1:
The patent removes the adhesive component from the waterproofing structure, joining the tube and covering material directly through heat and pressure without any intermediary adhesive layer, thereby eliminating the adhesive softening and extrusion problems
Solution Approach 2:
The patent introduces heat and pressure as intermediary factors to enable direct bonding between the tube and covering material, replacing the chemical bonding function previously provided by adhesive with physical bonding through thermal and mechanical energy
2Reliability
If an adhesive is used to join the covering material and the tube, then the waterproofing structure is formed, but the volume and cost of the waterproof structure increase
Solution Approach 1:
The patent extracts and eliminates the adhesive layer from the waterproofing structure, reducing the overall volume to only the essential components (tube and covering material) while maintaining waterproofing functionality through direct joining
Solution Approach 2:
The patent merges the tube and covering material into a unified structure through direct joining, eliminating the separate adhesive component and reducing the total volume of the waterproofing assembly
3Reliability
If an adhesive is used to join the covering material and the tube, then the waterproofing structure is formed, but the cost of the waterproof structure increases
Solution Approach 1:
The patent removes the adhesive component from the manufacturing process, eliminating the cost associated with purchasing, storing, and applying adhesive while maintaining waterproofing performance through direct joining
Solution Approach 2:
The tube and covering material perform their own joining function through direct contact under heat and pressure, without requiring the additional service of adhesive application equipment and processes, thereby reducing manufacturing complexity and cost
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 solution provides a cost-effective and volume-efficient waterproofing performance that prevents liquid penetration, including water and oil, while maintaining structural integrity and bendability, even with large core wire cross-sectional areas.
Implementation Method 1
rendering the materials compatible through heat and pressure application
Implementation Method 2
rendering the materials compatible through heat and pressure application
Implementation Method 3
The tube covers a connection between the core wire of the first wire and the core wire of the second wire
Data Source
AI summary
A wire harness that includes a first wire and a second wire each including a core wire and a covering material that covers the core wire; and a tube, wherein: the tube covers a connection between the core wire of the first wire and the core wire of the second wire, each of the covering materials contains a cross-linked polyethylene, the tube contains a cross-linked polyethylene, the tube and each of the covering materials are directly joined, and a tensile shear strength between the tube and each of the covering materials is 350 kPa or more.