Photocurable Resin Binding for Wire Harnesses
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Solution Overview
Problem
Existing methods for manufacturing wire harnesses, such as thermal welding and tape winding, either affect conductors under coatings or require lengthy winding processes, leading to suboptimal binding states and workability.
Innovation Solution
A method and device using a photocurable resin to form a binding portion around electric wires, which is cured with light, eliminating the need for thermal welding and tape winding, thereby improving binding state and workability while protecting the wires and reducing external protectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermal welding is used to bind electric wires, then binding strength is improved, but conductors under coatings are affected and binding state deteriorates
Solution Approach 1:
The patent replaces thermal welding (thermal field) with photocurable resin bonding (chemical field). The resin is applied to bind electric wires and cured through photopolymerization when exposed to light, eliminating thermal effects that damage conductors while achieving sufficient binding strength through chemical adhesion.
2Reliability
If tape winding is used to bind electric wires, then binding state is improved, but winding time increases and productivity decreases
Solution Approach 1:
The patent replaces the mechanical tape winding process with automated resin application and light curing. The photocurable resin is applied to the wires and rapidly cured by light exposure, eliminating the time-consuming manual or automated winding operation while maintaining binding quality.
Solution Approach 2:
The patent utilizes the phase transition of photocurable resin from liquid (applicable state) to solid (cured state) through photopolymerization. This rapid phase change upon light exposure enables quick binding without the prolonged mechanical winding process, significantly improving productivity.
3Productivity
If photocurable resin is used to form binding portion, then binding workability is improved, but additional curing process is required
Solution Approach 1:
The patent replaces thermal welding equipment with photocurable resin application and light curing equipment. While this introduces a chemical process, it eliminates the complex thermal control and monitoring required for thermal welding, and the rapid light curing enables faster cycle times, improving overall workability.
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 photocurable resin binding method enhances the binding state and workability of wire harnesses by not affecting conductors and eliminating winding time, while also providing protection and maintaining the required shape, thus improving productivity and reducing external components.
Implementation Method 1
performing a resin curing to cure the photocurable resin provided on the portion of the plurality of electric wires by irradiating the photocurable resin with light
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
A wire harness includes: a harness main body (2). The harness main body includes a plurality of electric wires (4) and a binding portion (5). The biding portion is configured to bind the plurality of electric wires. The binding portion is formed by a cured photocurable resin (23).