Slit Rigid Wire Harness Assembly for Easier Routing

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Solution Overview

Problem

Existing wire harness assemblies face challenges in improving routability, particularly in vehicles where the wire harnesses are routed through rigid members with limited space and flexibility.

Innovation Solution

A wire harness assembly design that includes a rigid member with a slit along the axial direction allowing the electric wire bundle to be inserted and routed through a routing space portion, utilizing a jig to deform and displace the wire bundle for insertion, and incorporating binding members to maintain and vary the bundle's posture.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a rigid member with a routing space portion is used to protect and organize the wire harness, then the structural integrity and organization are improved, but the routability and ease of insertion are worsened due to limited space and lack of flexibility

Engineering Contradiction:

Improvestructural integrityVSAvoidroutability

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The rigid member is segmented by providing a slit that divides the outer wall into multiple portions, creating an opening that allows the wire harness to be routed through the rigid member. This segmentation maintains the overall structural integrity while creating a flexible routing path.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A binding member is introduced as an intermediary element that binds the wire harness at multiple positions. This binding member allows the wire harness to be securely held and routed through the slit in the rigid member, facilitating easier insertion while maintaining organization.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Stability of the object's composition

If the wire harness is tightly bundled to maintain organization, then the structural order is improved, but the flexibility and ease of routing are worsened

Engineering Contradiction:

Improvebundle organizationVSAvoidrouting flexibility

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The binding member is configured to allow dynamic adjustment of the wire harness bundle. The binding member can be positioned at multiple locations along the wire harness, allowing the bundle to be flexible enough to route through the slit while maintaining organization when needed.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

Different portions of the wire harness are treated differently - the wire harness is bundled in certain regions to maintain organization, while leaving other portions more flexible for routing through the rigid member. The binding member creates localized binding zones that maintain organization without compromising overall routing flexibility.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20250206243A1Wire harness assembly and method for manufacturing wire harness assembly

Publication Date: 2025.06.26 YAZAKI CORP

AI summary

A wire harness assembly includes a wire harness that includes an electric wire bundle in which a plurality of electric wires extending along an axial direction is bundled, a rigid member that is provided with a routing space portion in which the electric wire bundle is routed along the axial direction, and a slit that is provided in an outer wall of the rigid member, extends along the axial direction, and enables insertion of the electric wire bundle into the routing space portion from the outside.