Rigid Wire With Recess For Flexible Wire Bundling
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Solution Overview
Problem
Existing wire assembly structures in vehicles require a fixing member, such as a resin protector, to bundle flat wires with other wires, leading to increased costs and complexity.
Innovation Solution
A wire assembly structure that incorporates a flexible wire housed within a recessed rigid wire, eliminating the need for a fixing member by using a bundling member like insulating tape to secure the flexible wire in place, while the recessed shape enhances the rigid wire's rigidity and allows for flexible routing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixing member such as a resin protector is used to bundle together flat wires and other wires, then the wires can be securely bundled and routed, but the routing cost increases and the structure becomes more complex
Solution Approach 1:
The patent merges the bundling function into the rigid wire itself by forming a recess portion that accommodates the flexible wire. This integration eliminates the need for separate fixing members like resin protectors, thereby reducing structural complexity while maintaining secure wire bundling through the geometric interlocking of the recess shape.
Solution Approach 2:
The flexible wire is nested within the recess portion of the rigid wire, creating a compact bundled structure. This nesting approach secures the wires together without requiring additional external fixing members, thus reducing both structural complexity and cost while ensuring reliable wire positioning.
2Reliability
If a fixing member such as a resin protector is used to bundle together flat wires and other wires, then the wires can be securely bundled and routed, but the routing cost increases
Solution Approach 1:
By integrating the bundling function into the rigid wire structure through the recess portion, the patent eliminates the need for separate fixing members. This reduction in component count directly lowers manufacturing and routing costs while maintaining secure wire bundling through the geometric design of the recess.
Solution Approach 2:
The rigid wire provides its own bundling capability through the recess portion, making the system self-sufficient. The recess structure inherently secures the flexible wire without requiring additional fixing members, thereby reducing routing costs while ensuring reliable wire positioning and bundling.
3Strength
If a recess portion is formed in the rigid wire to accommodate the flexible wire, then the structural rigidity of the rigid wire is improved, but the manufacturing complexity increases
Solution Approach 1:
The rigid wire is segmented with a recess portion that creates distinct functional zones: the rigid body provides structural strength while the recess cavity provides bundling functionality. This segmentation allows the single rigid wire component to simultaneously deliver both rigidity and wire accommodation without requiring additional structural elements.
Solution Approach 2:
The recess portion merges the structural support function and the wire bundling function into a single integrated component. The rigid wire with recess serves both as a structural element providing rigidity and as a bundling element securing the flexible wire, thereby reducing overall structural complexity despite the added manufacturing step for forming the recess.
Data Source
AI summary
A wire assembly that is provided in a vehicle or the like includes a flexible wire, and a rigid wire. The rigid wire is made of a rigid material and has a recess portion extending along a longitudinal direction of the rigid wire. The flexible wire is disposed in the recess portion of the rigid wire.