Vehicle Headliner Printed Wire Harness Short Circuit Prevention

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Solution Overview

Problem

Conventional vehicle overhead systems face issues with electrical short circuits and increased weight due to traditional wire harnesses contacting roof structural supports, leading to pinching, cutting, and insulation damage.

Innovation Solution

The implementation of a printed electrical wire harness using conductive ink on the vehicle headliner, which reduces weight and prevents short circuits by eliminating the need for physical wires between the headliner and roof, with strain relief circuits and conductive pads ensuring connectivity and integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional wire harnesses are installed between the headliner and roof, then electrical connectivity is achieved, but the wires contact roof structural supports causing pinching, cutting, and insulation damage leading to short circuits

Engineering Contradiction:

Improveelectrical connectivity reliabilityVSAvoidwire damage and short circuits

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the mechanical wire harness system with a printed electrical circuit system. Instead of using physical wires that can be pinched or cut by roof structural supports, the electrical connections are created through conductive ink printing directly on the headliner substrate, eliminating the mechanical contact issues entirely

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical state and form of electrical conductors from traditional insulated wires to printed conductive traces. This parameter change transforms the electrical connection method from mechanical wire routing to a printed circuit board-like approach, where conductive ink forms electrical pathways directly on the headliner surface

Inventive Principle:

Principle #35Parameter changes

2Reliability

If traditional wire harnesses with insulation and wrappings are used, then electrical insulation is provided, but the headliner weight increases significantly

Engineering Contradiction:

Improveelectrical insulationVSAvoidheadliner weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent extracts and eliminates the heavy insulation and wrapping materials from the wire harness assembly. By using printed conductive traces directly on the headliner substrate, the need for separate insulation layers and protective wrappings is removed, significantly reducing the overall weight while maintaining electrical functionality

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent uses composite material structures where the headliner substrate itself serves as both the structural component and the mounting surface for electrical circuits. The conductive ink is applied directly to the substrate, creating an integrated lightweight composite structure that combines mechanical support and electrical functionality

Inventive Principle:

Principle #40Composite materials

3Adaptability or versatility

If individual overhead system components are connected to the vehicle body electrical system at assembly time, then electrical connectivity is established, but the manufacturing process becomes complex and time-consuming

Engineering Contradiction:

Improveelectrical system adaptabilityVSAvoidassembly process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the headliner assembly with the wire harness by printing the electrical circuits directly on the headliner substrate. This consolidation eliminates the need for separate wire harness assembly and attachment steps, reducing manufacturing complexity while maintaining full electrical adaptability for various overhead components

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent performs preliminary action by pre-printing the electrical circuit patterns on the headliner substrate before final assembly. This allows the electrical pathways to be prepared in advance, enabling faster and simpler integration of overhead components during vehicle assembly without requiring complex wiring operations at each station

Inventive Principle:

Principle #10Preliminary action

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 solution reduces the weight and cost of overhead systems, prevents electrical short circuits, and maintains connectivity during vehicle assembly and use, while allowing for efficient installation and reduced manufacturing complexity.

Implementation Method 1

printing the wire harness circuitry on a headliner component... the wire harness is printed using a conductive ink

Methodology Applied

Scientific EffectConductive ink deposition: Deposition (physical)

Data Source

PatentUS8733828B2Headliner with integral wire harness

Publication Date: 2014.05.27 OLYMPUS HLDG

AI summary

This invention relates to a roof structure in a vehicle, wherein the roof structure (100) is provided with printed electrical connection means (110) for connecting electrical devices in the vehicle. The invention further relates to a method for manufacturing such a roof structure and to a system comprising an electrical device, a roof structure (100) with printed electrical connection means (110), a printed conductive pad (112, 212, 312, 412) and an electrical connector, wherein the electrical connector (530, 730) is pierced through the roof structure (100) to connect the electrical device with the conductive pad (112, 212, 312, 412).