Flexible PCB Wire Harness Layout for Easier Vehicle Assembly
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Solution Overview
Problem
Existing wire harnesses face challenges in assemblability to vehicles, requiring improvements in design and configuration to enhance installation efficiency and reduce complexity.
Innovation Solution
A wire harness design featuring a trunk line module with a flexible printed circuit board and branch line modules with routing materials, where the flexible printed circuit board includes a wiring pattern with conductor circuit parts and joint parts that concentrate branching points, simplifying the configuration and improving assemblability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional wire harness designs are used, then the basic electrical connection function is achieved, but the assemblability to vehicles deteriorates due to complex configuration and difficult installation
Solution Approach 1:
The wire harness is divided into a trunk line module and multiple branch line modules that can be independently manufactured and assembled. The trunk line module contains the flexible printed circuit board with conductor circuit parts, while branch line modules contain routing materials with connectors, allowing modular assembly that simplifies installation and improves assemblability to vehicles
Solution Approach 2:
Multiple branching points are concentrated and merged into joint parts on the flexible printed circuit board. Instead of having distributed branching points throughout the wire harness, all branch line modules connect to predetermined connectors on the trunk line module, consolidating the branching functionality in centralized locations that simplifies the overall configuration
2Adaptability or versatility
If traditional rigid circuit boards are used, then structural stability is maintained, but flexibility and adaptability to vehicle layouts deteriorate
Solution Approach 1:
The rigid circuit board is replaced with a flexible printed circuit board that exhibits flexibility. This flexible board can be bent and conform to various vehicle layouts and installation spaces while maintaining its electrical connection functions, significantly improving adaptability to different vehicle configurations
Solution Approach 2:
The circuit board is segmented into multiple conductor circuit parts that are electrically connected through joint parts. This segmentation allows the flexible printed circuit board to be manufactured in sections and assembled into complex three-dimensional configurations that maintain electrical connectivity while adapting to vehicle shapes
3Ease of manufacture
If branching points are distributed throughout the wire harness, then routing flexibility is achieved, but manufacturing and management complexity increases
Solution Approach 1:
All branching points are merged and concentrated in the joint parts located on the flexible printed circuit board of the trunk line module. Instead of having branching points distributed throughout the entire wire harness, all branch line modules connect to predetermined connectors on the trunk line, consolidating the branching functionality and simplifying both manufacturing and inventory management
Solution Approach 2:
The trunk line module with its flexible printed circuit board serves as a universal hub that can accommodate multiple different branch line modules. The standardized connectors and concentrated branching points allow for modular assembly where branch lines can be easily added, removed, or reconfigured without affecting the overall structure
Data Source
AI summary
A wire harness includes: a trunk line module that includes a flexible printed circuit board exhibiting flexibility and a plurality of trunk line side connectors provided at an end part of the flexible printed circuit board; and a plurality of branch line modules each including a plurality of routing materials exhibiting conductivity, and a branch line side first connector that is provided at terminals on one side of the routing materials, and mechanically and electrically connected to the trunk line side connector. The flexible printed circuit board includes a wiring pattern that includes: a plurality of conductor circuit parts that configure a transmission path by being electrically connected to each of the routing materials via the trunk line side connector and the branch line side first connector; and a joint part that mutually connects at least two of the conductor circuit parts.