Vehicle Harness Aerodynamic Gutter and Foam Sandwich
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Solution Overview
Problem
Current vehicle harness systems experience aerodynamic drag and wear issues due to large-diameter wires and fixing mechanisms, with existing connecting devices not effectively addressing the friction and diameter variations of wires, leading to chaffing and repair difficulties.
Innovation Solution
A connection system featuring a sandwich of foams enclosing wires, with an aerodynamic gutter to minimize drag and protect wires, allowing independent wire replacement and accommodating wires of varying diameters, and including tracking pins to maintain wires in a flat configuration, reducing friction and chaffing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wires are gathered in a large-diameter strand and located outside the vehicle, then wire protection and organization are improved, but aerodynamic performance deteriorates due to increased drag
Solution Approach 1:
The patent embeds the wire strand within a hollow aerodynamic fairing that is nested within the vehicle's outer covering. This nesting structure allows the wires to be protected while maintaining a streamlined external profile that minimizes aerodynamic drag.
Solution Approach 2:
The aerodynamic fairing is designed as a thin-walled hollow structure that provides protection for the wire strand while maintaining aerodynamic efficiency. The fairing's streamlined shape reduces drag compared to a bulky wire arrangement.
2Stability of the object's composition
If fixing means are used to attach wires to the outer covering, then wire stability is improved, but aerodynamic drag increases due to the fixing mechanisms
Solution Approach 1:
The fairing is attached to the outer covering in a streamlined manner that minimizes disruption to airflow. The attachment structure is designed to be aerodynamically efficient, reducing drag while maintaining secure fixation of the wire strand.
3Object-generated harmful factors
If wires are allowed to move relative to the outer covering, then aerodynamic performance is improved, but wire wear from chaffing increases
Solution Approach 1:
The wire strand is nested within the hollow fairing, which acts as a protective enclosure. This prevents direct contact between the wires and the outer covering, eliminating chaffing wear while maintaining aerodynamic efficiency.
Solution Approach 2:
The aerodynamic fairing serves as an intermediary structure between the wire strand and the external environment. It protects the wires from friction and wear while allowing the assembly to maintain good aerodynamic characteristics.
4Reliability
If wires are moved away from the outer covering to avoid chaffing, then wire durability is improved, but aerodynamic performance deteriorates further
Solution Approach 1:
Instead of moving wires further away from the outer covering, the patent nests them within a hollow fairing that is itself attached to the outer covering. This maintains a compact profile with good aerodynamic characteristics while protecting the wires from chaffing.
Data Source
Figure 1~3
Figure 4~7
AI summary
The present invention relates to a connection system (10) provided with a set of wires (30). This connection system (10) comprises a lower foam (15) and an upper foam (20) forming a sandwich (25) enclosing said wires (30), each wire (30) being compressed individually between the upper foam (20) and the lower foam (15), said connection system (10) comprising an aerodynamic gutter (40), said sandwich (25) being disposed in said gutter (40).