Shielded Wire Harness Spacers for Stable Bend Routing
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Solution Overview
Problem
In wire harnesses with shield pipes, the bending process can cause electric wires to move and change their routing, leading to variations in protrusion lengths, which can result in insulation breakdown and poor workability during device connection.
Innovation Solution
The use of spacers inside the shield pipe, spaced apart and with through holes for the electric wire, which are attached to the wire and positioned to maintain the wire's route during bending, reducing movement and protrusion variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the electric wire is merely inserted into the shield pipe with a gap therebetween, then the assembly process is simple, but the electric wire may move in the shield pipe during bending process, causing variation in protrusion lengths
Solution Approach 1:
A positioning member is introduced as an intermediary component between the electric wire and shield pipe. This positioning member fits tightly around the electric wire and engages with the shield pipe to prevent relative movement during bending, while allowing the wire to remain insertable during assembly
Solution Approach 2:
The positioning member provides localized constraint only at specific positions where needed, rather than constraining the entire wire uniformly. This allows the wire to be freely insertable in the assembly direction while preventing movement in other directions during bending
2Reliability
If the electric wire is tightly fixed in the shield pipe, then movement is suppressed, but the assembly process becomes complex and workability deteriorates
Solution Approach 1:
The positioning member is designed with dynamic characteristics that allow it to be flexible during assembly (easy insertion) but provide rigid constraint during operation (bending). The member can deform slightly to accommodate insertion forces but maintains its positioning function under bending loads
3Adaptability or versatility
If the shield pipe is bent into a curved shape, then the wire harness can reflect the wiring route in the vehicle, but the electric wire routing may change and protrusion lengths may vary
Solution Approach 1:
The positioning member is installed on the electric wire before the bending process. This preliminary action ensures that when the shield pipe is subsequently bent into the required curved shape, the wire maintains its position relative to the pipe, preventing routing changes and protrusion length variation
Data Source
AI summary
A wire harness including: an electric wire; a shield pipe through which the electric wire extends and at least a portion of which is defined as a bend that is curved; and a plurality of spacers disposed inside the shield pipe, wherein: the plurality of spacers are spaced apart from each other in a lengthwise direction of the shield pipe, and respectively have through holes therein, the electric wire extends through the through holes, and an outer peripheral surface of the electric wire is closely attached to inner periphery surfaces of the through holes.