Trim Panel Dummy Connector for Wiring Harness Retention
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Solution Overview
Problem
Automotive manufacturing faces inefficiencies due to the need for duplicate electrical connectors in vehicle wiring harnesses, which are not always utilized, leading to unused connectors that can cause clutter and pose risks of debris accumulation and damage.
Innovation Solution
A trim panel with a dummy connector is designed to receive and retain unused electric connectors, featuring a main body with a trim surface and attachment structures that secure it to the vehicle panel, and a dummy electric connector that holds the connector without electrical contacts, preventing movement and protecting the wiring harness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If duplicate electrical connectors are included in the wiring harness for different vehicle configurations, then the wiring harness can accommodate multiple installation options, but unused connectors remain in place causing clutter and potential debris accumulation
Solution Approach 1:
A dummy connector is introduced as an intermediary component to receive and isolate the unused electrical connector. The dummy connector acts as a protective intermediary that prevents debris from entering the unused connector while maintaining the adaptability of the wiring harness for different vehicle configurations.
2Adaptability or versatility
If duplicate electrical connectors are included in the wiring harness for different vehicle configurations, then the wiring harness can accommodate multiple installation options, but the unused connectors pose risks of damage and clutter
Solution Approach 1:
The dummy connector serves as a protective intermediary that shields the unused electrical connector from potential damage. By providing a dedicated receiving structure, it prevents physical damage and environmental contamination, thereby improving reliability while preserving wiring harness adaptability.
Solution Approach 2:
The dummy connector provides beforehand protection by pre-establishing a protective environment for the unused electrical connector. This prior cushioning prevents potential damage from debris and physical contact before any harmful events can occur.
3Device complexity
If unused electrical connectors are left exposed, then the wiring harness maintains simplicity, but the connectors can accumulate debris and become damaged
Solution Approach 1:
The dummy connector is designed as a simple intermediary component that adds minimal complexity to the wiring harness. Its straightforward structure provides effective debris protection while maintaining overall system simplicity and ease of installation.
4Reliability
If a dummy connector is added to receive unused electrical connectors, then debris accumulation and damage are prevented, but the device complexity increases
Solution Approach 1:
The dummy connector serves as a simple intermediary component that provides reliable protection for unused electrical connectors. Its straightforward design with a receiving structure and retention features achieves effective protection while adding minimal complexity to the overall wiring harness system.
Data Source
AI summary
A trim panel having a main body, a plurality of attachment structures and a dummy electric connector. The main body has a trim surface and an attachment surface opposite the trim surface. The plurality of attachment structures are formed on the attachment surface and are configured to contact and engage a separate panel securing the main body to the separate panel and covering an aperture formed in the separate panel. The dummy electric connector is formed on the attachment surface. The dummy electric connector is configured to receive and retain an electric connector in the absence of any electrical contacts within or on the dummy electric connector. The dummy electrical connector enables retention of a wiring harness having a connector that is not currently used, the unused connector to be connected to and retained by the dummy connector.