Frangible Wire Hanking for Easy Harness Removal and Recycling
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Solution Overview
Problem
Existing hanking materials for wiring harnesses often fail to consistently facilitate easy removal and recycling while maintaining the compact bundling of wires during assembly, especially for varying harness diameters and complex applications.
Innovation Solution
A tubular hanking material made of polyvinyl chloride with a frangible portion, featuring specific aperture spacings and a diametral shrink ratio, which allows for easy tearing and secure bundling, is designed to accommodate different wire diameters and masses, ensuring consistent performance across various applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a cellophane-like material with a tear strip is used to replace common hanking materials, then the cycle time to remove the material is improved, but the material becomes difficult to tear in some applications
Solution Approach 1:
The patent applies parameter changes by precisely controlling the aperture dimensions (0.6mm diameter), spacing (less than 14mm between rows), and distribution pattern of apertures in the frangible portion. These parameter optimizations ensure the tear strip can be easily pulled while maintaining consistent tearing behavior across different wire bundle sizes and materials.
Solution Approach 2:
The patent implements local quality by creating a frangible portion with distinct aperture patterns in specific regions of the hanking material. The frangible portion has different aperture characteristics compared to the rest of the material, allowing it to tear easily along predetermined lines while the remaining material maintains its structural integrity for secure bundling.
2Strength
If the hanking material is designed to securely hold wire bundles, then the structural integrity is improved, but the removal process becomes more difficult
Solution Approach 1:
The patent applies segmentation by dividing the hanking material into distinct functional zones: a frangible portion with aperture patterns designed for easy tearing, and a remaining portion with continuous or different aperture patterns for secure holding. This segmentation allows the material to provide strong bundling strength while enabling easy removal through the weakened frangible section.
Solution Approach 2:
The frangible portion acts as an intermediary element between the secure bundling function and the easy removal requirement. It provides a controlled weakness that facilitates removal without compromising the structural integrity needed during the assembly process, effectively mediating between conflicting requirements.
3Adaptability or versatility
If the hanking material accommodates varying harness diameters, then the adaptability is improved, but the consistency of tear performance decreases
Solution Approach 1:
The patent implements universality by designing aperture patterns and spacing relationships that maintain effective tear performance across a wide range of wire bundle diameters. The dimensional relationships (unshrunk diameter to spacing ratio greater than 1.8, unshrunk diameter to aperture distance ratio greater than 15) create a scalable system that works consistently for different application sizes.
Solution Approach 2:
The patent uses parameter changes by establishing specific dimensional ratios and relationships that scale with the hanking material size. The aperture spacing and distribution are defined as ratios relative to the unshrunk diameter, allowing the tear performance to remain consistent across different scales while adapting to various harness diameters.
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 hanking material effectively holds wire bundles during assembly, allowing for easy removal and recycling, while maintaining structural integrity and adaptability to diverse wiring harness configurations.
Implementation Method 1
The hanking material has a diametral shrink ratio of the unshrunk diameter to the shrunk diameter of 50% +/−10% at 130° C. to 200° C.
Implementation Method 2
The strip is configured to tear the frangible portion from a remaining portion of the hanking material along the first and second rows when pulled
Data Source
AI summary
A wiring harness includes multiple wires having a portion, a tubular hanking material that extends a length over the portion. The hanking material includes an unshrunk diameter and a shrunk diameter and has a frangible portion that is bounded by first and second rows that are separated by a spacing. The first row is provided by first apertures that are spaced a first distance, and the second row is provided by second apertures that are spaced a second distance. A strip of material in the frangible portion extends along the length. The strip is configured to tear the frangible portion from a remaining portion of the hanking material along the first and second rows when pulled. A first ratio of the unshrunk diameter to the spacing is greater than 1.8, and a second ratio of the unshrunk diameter to one of the first and second distances is greater than 15.