Folded Wire Harness End Protection for Bent Connector Lead-Outs
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Solution Overview
Problem
Existing methods for protecting the bent portion of wire harnesses are not versatile enough and require multiple types of covers and molds for different connector sizes and shapes, making them inefficient and costly.
Innovation Solution
A method involving a foldable sheet member that is secured to the wire harness using a pressure-sensitive adhesive, where the sheet is folded to cover the bent portion of the wire bundle and connector, forming protective edges and surfaces to shield the wire end from dust and maintain the bending shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a specific cover is used for each connector size, shape, bending angle, and wire bundle width, then the bent portion of electric wires is protected, but the number of types of covers and molds increases
Solution Approach 1:
The sheet member is designed with a universal structure that can accommodate various connector sizes, shapes, bending angles, and wire bundle widths through folding and securing operations, eliminating the need for multiple specialized covers and molds
2Reliability
If a sheet member is used to cover both the bent portion and connector end portion, then comprehensive protection is achieved, but the sheet member cannot be properly secured in horizontal connectors
Solution Approach 1:
The sheet member is divided into functionally distinct regions: a first region that covers the bent portion of the wire bundle, a second region that covers the connector end portion, and a third region that extends beyond both to serve as a securing area. This segmentation allows each region to fulfill its specific function while maintaining the integrity of the overall protective structure
Solution Approach 2:
The sheet member extends in multiple dimensions beyond the immediate protection needs, with the third region extending beyond both the bent portion and connector end to provide additional securing surface area, enabling proper attachment without compromising the coverage of protected areas
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
This method provides high versatility in protecting the bent portion of wire harnesses with a simple sheet member design, reducing the need for multiple types of covers and molds, thereby decreasing production costs and weight, while effectively preventing dust ingress and maintaining the wire bundle's orientation.
Implementation Method 1
a securing step of securing the sheet member to a wire bundle portion while keeping the counter sides in a facing state of facing the wire lead-out surface
Data Source
AI summary
A wire end of a wire harness is protected. The wire harness includes a wire bundle and a connector connected therewith. The wire bundle includes the wire end, and the wire end includes a bent portion and faces the connector. First, a sheet member is folded perpendicularly to a wire lead-out surface of the connector, thereby forming, concurrently, counter sides facing the wire lead-out surface, side surface covering portions, and a tip end protection portion. Next, the side surface covering portions are folded along a top protection portion formation portion, thereby forming, concurrently, side surface protection portions, a top protection portion and an extending portion. Next, a wire end protection portion is secured, with a pressure-sensitive adhesive tape or the like, to a wire bundle portion while the relative position of the counter sides with respect to the wire lead-out surface is maintained.