Wiring Harness Junction Assembly with Interlocking Trunk Terminals
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Solution Overview
Problem
The existing methods for coupling branch wires to a main trunk line in wiring harnesses, particularly in vehicular applications, are labor-intensive and result in redundant wire usage, leading to increased cost and weight due to the need for multiple splice connections.
Innovation Solution
An electrical junction assembly with an insulative housing featuring trunk and branch openings, where trunk terminals interlock within the housing to directly connect branch wires to the main trunk line, eliminating the need for redundant wire routing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual splicing connections are used to couple branch wires to the main trunk line, then electrical connection can be achieved, but labor intensity increases and assembly time is extended
Solution Approach 1:
The wiring system is segmented into modular junction assemblies, each housing containing pre-configured trunk terminals and branch terminals. This segmentation allows pre-assembly of connection points along the main trunk line, eliminating the need for manual splicing operations during final assembly and significantly reducing labor intensity and assembly time.
Solution Approach 2:
Trunk terminals are pre-affixed to the main trunk line at predetermined locations before final assembly. This preliminary action creates ready-to-connect points that simply require branch wire insertion, transforming a complex manual splicing process into a simple plug-and-play connection that dramatically reduces assembly time.
2Ease of operation
If multiple splice connections are created along the main trunk line, then branch wire connections are simplified, but redundant wire usage increases leading to increased weight and cost
Solution Approach 1:
The junction assembly divides the wiring system into discrete functional segments, with each housing containing exactly the number of trunk terminals needed for that section. This prevents unnecessary wire extensions to distant splice points and eliminates redundant wire loops, directly reducing overall wiring harness weight while maintaining easy connection capabilities.
Solution Approach 2:
Instead of creating physical splice connections at multiple locations along the trunk line, the invention uses replicated junction assembly housings that can be positioned at optimal intervals. Each housing serves as a self-contained connection point, eliminating the need for lengthy branch wire runs to remote splice locations and reducing total wire quantity.
3Ease of operation
If multiple splice connections are created along the main trunk line, then branch wire connections are simplified, but the complexity of the assembly process increases
Solution Approach 1:
The junction assembly merges multiple functions into a single integrated housing: electrical connection, mechanical support, and environmental sealing. By combining these functions that were previously distributed across separate splicing operations, the overall assembly process becomes simpler despite enabling multiple connection points along the trunk line.
Solution Approach 2:
The standardized junction assembly housing serves as a universal connection point that can accommodate multiple branch wires and different wire configurations. This multi-functionality allows the same housing design to be used throughout the wiring harness, simplifying the assembly process through repetition of a proven, optimized design rather than creating unique splice solutions for each location.
4Reliability
If traditional splicing with tape wrapping and heat shrink tubes is used, then electrical connections are sealed against moisture and shorts, but the number of components and assembly steps increases
Solution Approach 1:
The housing integrates the sealing and protection functions directly into the connection assembly itself. Rather than requiring separate tape wrapping and heat shrink tube steps, the housing provides built-in environmental sealing at the connection point, reducing the number of discrete components and assembly steps while maintaining or improving protection reliability.
Solution Approach 2:
The housing serves multiple functions simultaneously: it provides structural support for terminals, creates environmental seals, prevents moisture ingress, blocks electrical shorts, and mechanically anchors the wiring. This consolidation of multiple protective and structural functions into a single component reduces overall system complexity while enhancing reliability.
Data Source
AI summary
An electrical junction assembly for a wiring harness (10) couples one or more branch wires (18) to a main trunk line (12). The junction assembly includes a housing (16) having an internal cavity into which is received first (34) and second (36) trunk terminals which interlock with one another and establish electrical conductivity therethrough. A branch wire (18) is inserted into the housing (16) through a branch opening (28). The branch wire (18) has a branch terminal (48) on its end which is adapted to mechanically connect to the interlocked first (34) and second (36) trunk terminals, thereby establishing electrical conductivity between the branch wire (18) and the main trunk line (12). A mounting member (56) is formed integrally on the housing (16) to provide a secure connection to a suitable mounting structure (58). A hook (40) within the cavity in the housing (16) automatically engages and securely retains the second trunk terminal (36) when inserted into a full operative position. Cable seals (54) on each of the wires (18, 30, 32) seal against the respective openings (22, 24, 28) into the housing (16) to protect the electrical connections established therein.