Splice Housing Insulation Structure for Wiring Harness
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Solution Overview
Problem
Conventional insulation methods for splice portions of electrical wires require significant labor-hours, involving the use of insulation tubes and tie bands or heat shrink tubes, which are time-consuming and inefficient.
Innovation Solution
An insulation structure with a splice housing portion and a separation restricting portion that allows for easy insertion and retention of splice terminals, combined with an electrical wire housing portion that restricts wire movement and includes a coating pressing portion to prevent damage, all integrated into a harness mounting plate made of insulative material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional insulation methods using insulation tubes and tie bands or heat shrink tubes are used, then reliable insulation is achieved, but labor-hours and time consumption increase significantly
Solution Approach 1:
The patent merges the insulation function and the structural support function into a single integrated housing structure. The housing includes an insertion hole for receiving the splice terminal and an insulation portion that directly provides insulation, eliminating the need for separate insulation tubes and tie bands. This integration reduces the number of components and assembly steps while maintaining reliable insulation.
Solution Approach 2:
The housing structure is designed to perform its own insulation function through the insulation portion formed as an integral part of the housing. The insulation portion directly contacts and insulates the splice terminal without requiring additional insulation components. This self-service approach eliminates the need for separate insulation operations and reduces labor-hours.
2Reliability
If multiple separate components (insulation tube, tie band, or heat shrink tube) are used for insulation, then insulation is achieved, but device complexity and number of parts increase
Solution Approach 1:
The patent combines multiple functions into a single housing structure. The housing includes a body portion for structural support, an insertion hole for terminal reception, and an insulation portion for electrical insulation. All these features are integrated into one component, reducing the total number of parts from multiple separate components (housing, insulation tube, tie band, or heat shrink tube) to just the housing alone.
Solution Approach 2:
The housing structure is designed to perform multiple functions simultaneously: it provides structural support for the splice terminal, creates a mounting interface through the insertion hole, and provides electrical insulation through the insulation portion. This multi-functionality eliminates the need for separate specialized components for each function.
3Reliability
If insulation tubes or heat shrink tubes are used, then insulation is provided, but additional fastening or heating operations are required
Solution Approach 1:
The insulation portion of the housing is designed to automatically provide insulation coverage when the splice terminal is inserted through the insertion hole. The terminal is retained by the housing structure itself, and the insulation portion directly contacts the terminal to provide protection. No separate fastening or heating operations are needed because the housing structure performs all these functions simultaneously through its integrated design.
Solution Approach 2:
The patent merges the retention function and insulation function into a single integrated structure. The housing body retains the splice terminal through the insertion hole configuration, while the insulation portion simultaneously provides protective coverage. This combination eliminates the need for separate fastening steps (like tying bands) or heating steps (like shrinking tubes).
Data Source
AI summary
An insulation structure for a splice portion, a harness mounting plate, and a wiring unit that are capable of reducing labor-hours that are required when insulating a splice portion where a plurality of electrical wires are connected by a splice terminal. A plurality of electrical wires are connected by a splice terminal, wherein an opening portion that allows the splice portion to be inserted thereinto and removed therefrom is formed in a splice housing portion that surrounds and insulates the splice portion, and the insulation structure is provided with a separation restricting portion that restricts the splice portion that is housed in the splice housing portion from becoming separated from the opening portion.