Segmented Bonding Layout for Lightweight Wiring Fixation
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Solution Overview
Problem
Existing wiring systems face challenges in achieving sufficient fixing strength while minimizing material weight and cost, particularly when the materials of the insulating covering and exterior member are not compatible or have a small welding area.
Innovation Solution
A wiring member design featuring a sheet material with a first layer and a second layer that includes partial second layers separated along the extension direction of a wire-like transmission member, providing fixed points at branch, bend, and intersection points to enhance fixation without covering the entire main surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a holding part mediating bonding is provided on the whole main surface of the exterior member, then fixing strength is improved, but quantity and cost for materials increase
Solution Approach 1:
The second layer is divided into multiple partial second layers that are separated from each other along the extension direction of the wire-like transmission member. This segmentation allows the bonding function to be distributed across multiple discrete regions rather than requiring continuous coverage, thereby reducing material quantity while maintaining fixing strength at critical locations such as branch parts, bend parts, and intersection parts
Solution Approach 2:
The partial second layers are strategically positioned at specific locations where the wire-like transmission member has branch parts, bend parts, or intersection parts. This local quality approach concentrates bonding resources at critical areas that require enhanced fixing strength, rather than uniformly distributing material across the entire surface, thus optimizing the balance between fixing strength and material usage
2Strength
If the welding area is increased, then fixing strength is improved, but weight and cost for materials increase
Solution Approach 1:
The welding area is segmented into multiple discrete partial second layers rather than forming a continuous large-area bonding zone. Each partial second layer creates a localized welding area at critical positions, which collectively provides sufficient fixing strength while minimizing the total weight of material required
Solution Approach 2:
The welding areas are concentrated at local critical regions (branch parts, bend parts, intersection parts) where the wire-like transmission member requires enhanced fixing. This localized approach to welding area distribution improves fixing strength at necessary locations without increasing overall weight
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 design allows for firm fixation of the wire-like transmission member to the sheet material, reducing material weight and cost while maintaining the structural integrity of the wiring system.
Implementation Method 1
at least part of a portion where an insulating covering of the electrical wire and the exterior member overlap each other is welded
Data Source
AI summary
A wiring member includes a sheet material including a first layer formed into a sheet-like shape and a second layer provided on a main surface of the first layer, and a wire-like transmission member fixed on the sheet material. The second layer is a layer mediating a bonding of the first layer and the wire-like transmission member, and includes a plurality of partial second layers provided to be separated from each other along an extension direction of the wire-like transmission member.