Insulation Cap with Engagement Units for Wire Harness Holding
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Solution Overview
Problem
The existing holding structure with an insulation cap fails to maintain a strong holding force when an external force is applied in the direction of the branch being drawn from the insulation cap, leading to issues such as tape peeling or cutting.
Innovation Solution
A holding structure with an insulation cap featuring an exterior member with alternately arranged recesses and protrusions along its circumference, and an insulation cap with engagement units that fit into these features, distributing the external force and reducing the stress on the binding tape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the insulation cap is bound to the trunk with a tape only, then the structure is simple, but the holding force is insufficient and the tape may peel or cut under external force
Solution Approach 1:
The patent combines the binding function and the force distribution function into a single integrated structure. The engagement units are formed directly on the insulation cap, merging the role of the binder with the role of the force-distributing element, thereby increasing holding force without adding separate components.
Solution Approach 2:
The engagement units extend in the radial direction from the insulation cap, creating a three-dimensional structure that distributes external forces across multiple engagement points. This dimensional extension allows the tape to bind more effectively by engaging the cables at multiple locations rather than a single plane.
2Strength
If the insulation cap is bound tightly to prevent peeling, then the holding force increases, but the tape may cut under concentrated external force
Solution Approach 1:
The engagement force is segmented into multiple discrete engagement units distributed around the circumference of the insulation cap. Each engagement unit handles a portion of the external force, preventing concentration of stress on a single point and thereby avoiding tape cutting while maintaining strong overall holding force.
3Strength
If multiple engagement units are added to distribute force, then the holding force increases, but the manufacturing complexity increases
Solution Approach 1:
The engagement units are integrated directly into the insulation cap structure, combining the cap and the engagement mechanism into a single molded component. This eliminates the need for separate engagement parts and reduces assembly steps, making manufacturing easier despite the increased functional complexity.
Solution Approach 2:
The number, size, and distribution of engagement units can be adjusted by changing molding parameters during manufacturing. This allows optimization of holding force while maintaining ease of manufacture through standard plastic molding processes, without requiring complex assembly operations.
Data Source
AI summary
A holding structure with an insulation cap includes a corrugated tube which sheathes a trunk included in a wire harness and which has an outer circumference provided with a recess and a protrusion alternately arranged in a longitudinal direction. The insulation cap is attached to an end of a branch included in the wire harness and is provided with a protrusion which fits in the recess of the corrugated tube. The protrusion of the insulation cap is engaged with the recess of the corrugated tube, and a tape is wound around the insulation cap and the corrugated tube.