Wire Coupling Structure With Anti-Rotation Grommet and Bracket
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Solution Overview
Problem
Existing wire coupling structures in electric vehicles face issues with rotation and distortion during coupling, leading to unstable electrical connections and potential safety hazards, and lack efficient methods for miniaturization, weight reduction, and connector-free connections.
Innovation Solution
A wire coupling structure comprising a fixer, grommet, and bracket design that prevents rotation through fixing protrusions and grooves, allowing for easy manufacturing and installation, miniaturization, and secure electrical connections without additional connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a grommet or bracket is used to couple different wirings, then wiring connection is achieved, but rotation and distortion may occur during coupling
Solution Approach 1:
The patent employs asymmetric features including a D-shaped groove in the bracket and a corresponding protrusion on the grommet, along with positioning protrusions that have asymmetric shapes. These asymmetric features prevent rotation and ensure proper orientation during coupling, eliminating the distortion problem while maintaining reliable connection.
Solution Approach 2:
The patent introduces positioning protrusions and positioning grooves as intermediary elements between the bracket and grommet. These intermediary features facilitate precise alignment and prevent rotation during the coupling process, ensuring that the wiring connection is established without distortion.
2Reliability
If traditional coupling methods are used, then wiring connection is achieved, but additional connectors and complex structures are required
Solution Approach 1:
The patent merges the grommet and bracket into an integrated coupling structure where the grommet is directly formed on the bracket body. This integration eliminates the need for separate connectors and reduces structural complexity while maintaining reliable electrical connection stability through the unified design.
Solution Approach 2:
The bracket structure serves multiple functions: it provides mechanical support, enables electrical connection through the integrated grommet, and prevents rotation through asymmetric features. This multi-functionality reduces the need for additional components and simplifies the overall wiring system.
3Reliability
If conventional wiring structures are used, then electrical connection is achieved, but weight and size increase
Solution Approach 1:
By integrating the grommet directly onto the bracket body, the patent reduces the total number of components and materials required. This merging of structures decreases the overall weight of the wiring system while maintaining reliable electrical conductivity through the unified conductive path.
4Adaptability or versatility
If multiple separate components are used for coupling, then connection flexibility is achieved, but manufacturing and installation complexity increases
Solution Approach 1:
The integration of the grommet and bracket into a single component simplifies manufacturing to one molding or fabrication process, and reduces assembly to a single coupling action. The asymmetric features ensure proper orientation is automatically achieved, eliminating the need for complex alignment procedures.
Data Source
AI summary
A wire coupling structure and a method for installing the same are disclosed. A wire coupling structure according to an aspect of the present disclosure may include a fixer coupled to an external wire; a grommet surrounding the fixer and coupled to the wire and the fixer; and a bracket surrounding the grommet and coupled to the grommet, wherein the fixer includes a fixing body surrounding the wire from the radial outside; and a fixing protrusion continuous with the fixing body and protruding outward and exposed outward of the grommet, and wherein the bracket includes an arm body surrounding the grommet from the radial outside; and a fixing groove formed through the inside of the arm body and coupled to the fixing protrusion.