Sewn Wire Harness with Multi-Functional Sheet
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Solution Overview
Problem
The existing technologies for attaching exterior components to electric wires in vehicle wire harnesses require multiple process types due to different functions such as soundproofing, protection, heat radiation, and shielding, leading to increased complexity and inefficiency.
Innovation Solution
A wire harness structure that includes a functional exterior component shaped into a sheet with electric wires sewn onto it using threads, which can serve multiple functions like soundproofing, shielding, protection, and heat radiation, and can be easily manufactured using a sewing machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If different structures are used for attaching various exterior components (soundproofing, protection, heat radiation, shielding) to electric wires, then each component's specific function is optimized, but the number of process types increases
Solution Approach 1:
The exterior component is designed to perform multiple functions simultaneously - soundproofing, protection, heat radiation, and shielding - all through a single integrated structure that uses one attachment process (sewing) for all these functions, eliminating the need for multiple different attachment structures
2Ease of manufacture
If a unified sewing method is used for attaching exterior components to electric wires, then the manufacturing process is simplified, but the ability to provide specific functions (soundproofing, shielding, protection) must be maintained
Solution Approach 1:
The exterior component integrates multiple functions (soundproofing layer, protective layer, heat radiating layer, shielding layer) into a single multi-layer structure that can be attached using one unified sewing process, maintaining all required functions while simplifying manufacturing
Solution Approach 2:
The exterior component uses a composite multi-layer structure where each layer provides a specific function (soundproofing, protection, heat radiation, shielding), and the combination of these layers achieves all required functions through a single component
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
This solution allows for a unified attachment method applicable to various exterior components, enhancing soundproofing, shielding, protection, heat radiation, and tensile strength while simplifying the manufacturing process, making it easier to position connectors and fastening components.
Implementation Method 1
at least one thread for sewing the electric wire on the functional exterior component
Implementation Method 2
a soundproof component with soundproofing properties
Implementation Method 3
a shielding component capable of shielding the electric wire
Implementation Method 4
a protective component capable of protecting the electric wire from abrasion, the protective component having abrasion resistance
Implementation Method 5
a heat radiating component capable of radiating heat of the electric wire
Implementation Method 6
a tensile strength in a direction along an extension direction of the electric wire is higher than a tensile strength in a direction orthogonal to the direction
Data Source
AI summary
A wire harness includes a functional exterior component, at least one electric wire, and at least one thread. The functional exterior component is shaped into a sheet. The electric wire is disposed on one main surface of the functional exterior component. With the thread the electric wire is sewn on the functional exterior component.