Foam-Encapsulated Cable Harness for Fastener-Free Vehicle Mounting
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Solution Overview
Problem
Existing wiring harnesses for motor vehicles lack an efficient and secure method for attaching cables to vehicle components without additional fasteners, while also accommodating manufacturing tolerances and providing protection against vibrations and moisture.
Innovation Solution
A wiring harness design featuring a foam coating that embeds and mechanically combines multiple electrical cables, forming a recording that can absorb and securely attach to vehicle components through frictional connections, eliminating the need for additional fasteners and enhancing protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional fasteners are used to attach cables to vehicle components, then the attachment security is improved, but the device complexity and installation effort increase
Solution Approach 1:
The patent combines multiple cables into a single cable bundle and integrates the attachment function directly into the foam sheathing material. The foam sheathing serves both as cable protection and as the attachment element that frictionally connects to the vehicle component, eliminating the need for separate fasteners and reducing overall device complexity.
Solution Approach 2:
The foam sheathing performs multiple functions simultaneously: it protects individual cables from damage, provides mechanical strength to the cable bundle, and creates the friction-fit connection to the vehicle component. This multi-functionality eliminates the need for additional specialized attachment components.
2Strength
If rigid attachment methods are used to secure cables, then the attachment strength is improved, but the ability to accommodate manufacturing tolerances and vehicle geometries deteriorates
Solution Approach 1:
The patent utilizes the viscoelastic properties of foam material, which allows it to change its mechanical parameters (softness, flexibility) based on temperature and pressure conditions. During installation, the foam is soft and adaptable to various geometries; after installation, it hardens to provide strong attachment, thus accommodating both adaptability and strength requirements.
Solution Approach 2:
The foam sheathing acts as a flexible shell that can conform to the contours of different vehicle components. Its flexible nature allows it to adapt to manufacturing tolerances and various vehicle geometries while still providing sufficient attachment strength through friction.
3Adaptability or versatility
If multiple separate cable bundles are routed independently, then the routing flexibility is improved, but the installation effort and space requirements increase
Solution Approach 1:
The patent merges multiple separate cable bundles into a single integrated cable bundle surrounded by common foam sheathing. This reduces the number of individual routing operations required during installation while maintaining the ability to route the combined bundle flexibly around vehicle components.
Solution Approach 2:
While combining cables into a bundle, the patent maintains internal segmentation by allowing individual cables to be separately positioned and protected within the foam sheathing. This enables future access to individual cables if needed, while simplifying current installation procedures.
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 design allows for secure, vibration-resistant, and moisture-protected attachment of cables to vehicle components, simplifies assembly, and reduces installation space requirements, while accommodating various vehicle geometries and tolerances.
Implementation Method 1
The first cable bundle is embedded, at least partially, in the foam sheathing, and the foam sheathing mechanically connects the first electrical cable to the second electrical cable
Implementation Method 2
The foam sheathing, in at least a first section of the wiring harness, is designed to press an inner surface of the receptacle against the vehicle component
Implementation Method 3
The foam sheathing allows the wiring harness to conform to the contours of the vehicle component, thus compensating for manufacturing tolerances in the component
Data Source
Figure 1~3
Figure 4~5A
Figure 5B~5C
AI summary
The invention relates to a cable harness (15) and to an arrangement (11) with such a cable harness, wherein the cable harness (15) has a foam encapsulation (40) and at least a first cable bundle (45) with a first electrical cable (50) and a second electrical cable (55), wherein the first cable bundle (45) is at least partly embedded in the foam encapsulation (40) and the foam encapsulation (40) mechanically connects the first electrical cable (50) to the second electrical cable (55), wherein the cable harness (15) forms in at least a first subsection (35) a first receptacle (60), wherein the first receptacle (60) is designed to receive at least partly a vehicle component (20) of the motor vehicle (10), wherein the foam encapsulation (40) in the first subsection (35) is designed to press an inner side (65) of the cable harness (15) against the vehicle component (20) to form a first frictional connection (145) with the vehicle component (20).