Multilayer Textile Sleeve for Wire Harness Transition Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing protective members for connectors and sensors in automotive applications face challenges in attaching securely while allowing for easy removal and reuse, and they fail to provide adequate protection against impact, cut-through, and heat in the transition region between connectors and wire harnesses.
Innovation Solution
A multilayered tubular sleeve with a woven inner layer and a braided outer layer, where the braided layer is welded to the woven layer, providing enhanced impact and cut-through resistance while allowing flexibility and ease of assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive attachment is used to secure the protective member to the connector or sensor, then secure attachment is achieved, but the protective member cannot be easily removed or reused
Solution Approach 1:
The protective member is divided into modular components: a reusable protective member and a disposable attachment member. The attachment member can be easily removed and replaced without affecting the protective member, enabling secure attachment while maintaining ease of removal and reuse.
Solution Approach 2:
An attachment member acts as an intermediary between the protective member and the connector/sensor. This intermediate component provides the adhesive attachment function while allowing the protective member itself to remain removable and reusable.
2Ease of operation
If tape or friction fit is used to attach the protective member, then ease of installation is improved, but reliability and protection against heat and vibration deteriorate
Solution Approach 1:
The attachment function is segmented into a separate attachment member that can be easily applied using tape or friction fit, while the main protective member maintains its structural integrity and protection capabilities. This allows easy installation without compromising reliability.
3Strength
If rigid tubular shroud is used for protection, then impact and cut-through resistance is improved, but flexibility and ease of assembly deteriorate
Solution Approach 1:
The protective member utilizes a flexible braided construction that can bend and conform to the underlying connector/sensor and wire harness geometry. This flexible braid provides impact and cut-through resistance while maintaining the ability to flex and assemble easily around complex shapes.
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
The solution provides reliable protection against impact, cut-through, and heat, while allowing for easy installation, removal, and reuse, maintaining an aesthetically pleasing appearance and being economical in manufacture and assembly.
Implementation Method 1
the tubular braided wall is welded to an outer surface of the tubular woven wall via at least one weld joint formed by melted and solidified material of at least one of the tubular woven wall and the tubular braided wall
Data Source
AI summary
A protective member for a wire harness and electrical member fixed thereto, a wire harness assembly, and a method of constructing a protective member for a wire harness and electrical member fixed thereto are provided. The protective member includes a tubular woven wall extending between opposite open ends about a central axis and a tubular braided wall fixed to the tubular woven wall. One end of the tubular woven wall is configured to overlie the electrical member to provide protection thereto, and the tubular braided wall extends away from the other of the opposite open ends of the tubular woven wall about the central axis for operable attachment a wire harness.