Wire Harness Outer Cover with Overlapping Notches for Branch Routing
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Solution Overview
Problem
Existing outer cover bodies for electrical wires with branch line holes require complex work to pass branched electrical wires and often necessitate larger hole dimensions due to connector sizes, leading to inadequate position control.
Innovation Solution
A thermoplastic resin foam sheet outer cover body with overlapping notches forming a branch line through-hole, allowing for easier passage of branched wires without increasing hole dimensions, and featuring a separate outer and inner side wall structure to prevent deformation and enhance strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a branch line hole is formed in the outer cover body to pass the branched electrical wire, then the electrical wire can be branched, but the work of passing the branched electrical wire becomes complicated
Solution Approach 1:
The outer cover body is divided into multiple wall parts (first wall part, second wall part, third wall part, fourth wall part) that are separately formed and then assembled. The branch line through-hole is formed by overlapping notches from different wall parts, allowing the branched electrical wire to be passed more easily through the segmented structure during assembly
Solution Approach 2:
Notches are预先 formed in each wall part before assembly. These notches are positioned and sized in advance to facilitate the passage of the branched electrical wire, so that when the wall parts are assembled, the branch line through-hole is already prepared and the wire can be passed without complicated operations
2Adaptability or versatility
If the dimension of the branch line hole is set larger than the external diameter of the branched electrical wire to accommodate connector members, then connector members can be passed, but position control of the branched electrical wire becomes insufficient
Solution Approach 1:
The outer cover body has different structural characteristics at different locations. The wall parts have different thicknesses and the notches are positioned at specific locations to provide both accommodation space for connector members and precise positioning control for the branched electrical wire. The overlapping structure creates a localized fit that maintains position control while accommodating connectors
3Ease of manufacture
If a resin sheet is bent to form the outer cover body, then the structure can be formed, but deformation may occur affecting strength
Solution Approach 1:
The outer cover body is formed by assembling multiple separate wall parts rather than bending a single continuous resin sheet. This segmentation prevents deformation that would occur during bending while maintaining ease of manufacture through modular assembly. Each wall part can be formed independently with proper reinforcement
Solution Approach 2:
The outer cover body uses a composite structure with multiple wall parts that can be made from different resin materials or with different properties. This allows optimization of each wall part for its specific function while maintaining overall strength. The composite structure provides both formability and structural integrity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates the passage of branched electrical wires with improved position control and reduced weight, while preventing deformation and enhancing longitudinal strength by using a thermoplastic resin foam sheet with overlapping notches and a separate wall structure.
Implementation Method 1
a resin sheet is a thermoplastic resin foam sheet
Data Source
AI summary
An outer cover body for electrical wires, which is formed by bending a resin sheet and to be attached to an outer periphery of an electrical wire, includes a plurality of wall parts extending along an extending direction of the electrical wire and forming an accommodating part for accommodating the electrical wire. At least one of the plurality of wall parts includes a wall surface overlapping part having an outer side wall surface having a first notch, and an inner side wall surface overlapping the outer side wall surface and having a second notch. A branch line through-hole is formed by overlapping the first notch and the second notch.