Modular Wiring Harness With Overmolded Matrix And Snap-In Plug
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Solution Overview
Problem
Conventional wiring harnesses are prone to dislodgment due to vibration and temperature changes, leading to wire chafing and damage, and are costly to manufacture due to the need for multiple molds for various wire arrangements and sizes, with existing connector plugs limiting geometry and providing inadequate sealing.
Innovation Solution
A modular wiring harness with a molded wire matrix and mounting plug, allowing for flexible geometric design and manufacturing, featuring a modular connector plug that can be permanently or reversibly affixed using a snap-in mechanism or adhesive, and manufactured through overmolding for cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional wiring harnesses are used with traditional connector plugs, then manufacturing is limited to specific geometric configurations, but this limits design flexibility and increases manufacturing cost due to multiple molds required
Solution Approach 1:
The connector plug is divided into two separate components: a molded wire matrix portion and a mounting plug portion. This segmentation allows each component to be manufactured independently using standard molding processes, then assembled together. The wire matrix can be molded with wires in various arrangements without requiring different molds, as the mounting plug is a separate component that attaches to the wire matrix after molding.
Solution Approach 2:
The wires are pre-arranged and molded into the wire matrix portion before the mounting plug is attached. This preliminary arrangement of wires during the molding process eliminates the need for post-molding wire manipulation and allows for flexible wire configurations without requiring different molds for different wire arrangements.
2Reliability
If conventional connector plugs are used to secure wiring harnesses, then assembly is simplified, but the wiring harnesses become prone to dislodgment due to vibration and temperature changes
Solution Approach 1:
The sealing function and mechanical attachment function are merged into a single integrated seal member that is part of the mounting plug assembly. This seal member simultaneously provides environmental sealing and mechanical retention of the wiring harness, eliminating the need for separate sealing components and ensuring that the wiring harness remains securely positioned while maintaining reliable sealing against environmental factors.
3Adaptability or versatility
If multiple molds are used to accommodate various wire arrangements and sizes, then wire configuration flexibility is achieved, but manufacturing cost increases
Solution Approach 1:
The wire matrix portion is designed as a universal component that can accommodate various wire arrangements and sizes through a single molding process. The matrix structure allows wires to be positioned in different configurations within the same molded component, eliminating the need for multiple specialized molds. The mounting plug then attaches to this universal wire matrix to create the final connector assembly.
Data Source
AI summary
This invention discloses a wiring harness, a method of manufacturing said wiring harness, and a lamp assembly which utilizes said wiring harness. The wiring harness is comprised of a plurality of insulated conductive electrical wires which extend through a modular connector plug. The modular connector plug is comprised of a molded wire matrix and a mounting plug. To manufacture the wiring harness, a molded wire matrix is overmolded onto a plurality of insulated conductive electrical wires and then a mounting plug is overmolded onto the wire matrix.