Corrugated Tube With Variable Pitch Bellows For Wire Harness
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Solution Overview
Problem
The existing corrugated tubes for slide doors require numerous fixing members for path regulation, leading to increased operational steps, costs, and aesthetic deterioration.
Innovation Solution
A corrugated tube design featuring a tubular member with distinct bellows portions and straight portions, where the first bellows portion has a shorter pitch and the second bellows portion has a longer pitch, and straight portions are formed at the ends, reducing the need for fixing members by pre-defining the bending characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If numerous fixing members are used for path regulation of the corrugated tube, then the tube can be securely fixed to the vehicle body, but the number of operational steps increases and cost increases
Solution Approach 1:
The corrugated tube is designed with pre-formed straight portions at both ends and bellows portions in between, where the straight portions are inherently rigid and can be directly inserted into fixing grooves without requiring additional fixing members. This preliminary structural configuration eliminates the need for multiple fixing operations while maintaining secure fixation.
Solution Approach 2:
The corrugated tube is divided into distinct functional segments: straight portions for fixation and bellows portions for flexibility. This segmentation allows each portion to perform its specific function optimally, with the straight portions providing stable insertion points that reduce the number of fixing members needed.
2Reliability
If numerous fixing members are used for path regulation, then the corrugated tube can be securely fixed, but the cost increases due to multiple uses of fixing members
Solution Approach 1:
The straight portions are pre-formed during tube manufacturing with sufficient rigidity and dimensional stability to serve as self-fixing elements. This preliminary action eliminates the need to purchase and install separate fixing members, thereby reducing material costs while maintaining secure fixation.
3Reliability
If numerous fixing members are used for path regulation, then the corrugated tube can be securely fixed, but the appearance deteriorates due to visible fixing members
Solution Approach 1:
The straight portions are pre-designed to be inserted into fixing grooves formed on the vehicle body, creating a concealed fixation system. The fixing grooves are shaped to receive the straight portions, allowing the tube to be securely fixed without visible external fixing members, thus maintaining aesthetic appearance.
4Ease of manufacture
If the corrugated tube has uniform bellows structure, then manufacturing is simplified, but the tube cannot effectively regulate bending in different sections
Solution Approach 1:
The corrugated tube features different structural qualities in different sections: straight portions with high rigidity at the ends for fixation, and bellows portions with flexibility in the middle for bending. This local differentiation allows the tube to perform multiple functions while remaining manufacturable through standard extrusion processes with appropriate tooling.
Data Source
AI summary
A corrugated tube having a tube shape is provided with a tubular member configured to contain a conductor path, a first bellows portion, a second bellows portion, and a straight portion. The first bellows portion and the second bellows portion include recessed grooves extending in a circumferential direction of the tubular member and projection strips extending in the circumferential direction of the tubular member. The recessed grooves and projection strips are alternately arranged in a longitudinal direction of the tubular member. In the first bellows portion and the second bellows portion, a pitch which is a distance from one of the recessed grooves to a next recessed groove through one of the projection strips is set as a first distance and a second distance which is longer than the first distance.