Folded Wire Harness Outer Cover With Ultrasonic Welded Locking
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Solution Overview
Problem
Existing electric wire outer covers for vehicles have high manufacturing costs due to the need for multiple engagement parts, which also compromise the structural strength and durability.
Innovation Solution
A tubular housing portion formed from a folded sheet with projections and holes, where the projections are melted and welded to the upper wall using ultrasonic welding, reducing the number of parts and enhancing engagement strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple engagement parts are used to assemble the outer cover, then the structural strength is improved, but the manufacturing cost increases
Solution Approach 1:
The patent integrates multiple engagement parts into a single integrated engagement component that simultaneously engages with multiple ribs of the housing. This merging of parts reduces the total number of components, lowering manufacturing cost while maintaining the structural strength through distributed engagement points.
Solution Approach 2:
The engagement part is designed with multiple engagement protrusions that can simultaneously engage with multiple ribs, making a single component perform the function of multiple separate engagement parts. This multi-functionality reduces part count and assembly complexity while ensuring robust structural connection.
2Stability of the object's composition
If multiple engagement parts are used to assemble the outer cover, then the assembly stability is improved, but the device complexity increases
Solution Approach 1:
Multiple engagement functions are merged into a single engagement part with multiple protrusions, reducing device complexity by eliminating the need for multiple separate components while maintaining assembly stability through simultaneous engagement with multiple ribs.
Solution Approach 2:
The engagement part is segmented into multiple engagement protrusions distributed along its length, allowing each segment to engage with a corresponding rib. This segmentation within a unified component provides stable multi-point engagement while keeping the overall structure simple.
3Ease of manufacture
If a folded sheet structure is used for the housing portion, then the manufacturing cost is reduced, but the structural strength may be compromised
Solution Approach 1:
The folded sheet structure incorporates curved fold lines and angled surfaces that distribute mechanical loads more effectively than flat panels. The curved geometry of the folds provides inherent structural reinforcement, maintaining strength while using a simple folded sheet construction for cost-effective manufacturing.
Solution Approach 2:
The housing portion is divided into multiple folded segments or panels connected at reinforced fold lines. This segmentation allows the structure to maintain flexibility and absorb stress, preventing crack propagation while keeping the overall design simple and cost-effective to manufacture.
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
This approach reduces manufacturing costs while improving the structural strength and durability of the electric wire outer cover, ensuring it can withstand vibrations during vehicle installation without deformation or damage.
Implementation Method 1
the housing portion is formed by engagement between the first wall and the second wall through melting of the projection that has passed through the hole and welding of the melted projection to the second wall
Data Source
AI summary
An electric wire outer cover is provided which is to be fitted around an electric wire and which has a tubular housing portion where the electric wire is to be housed, the housing portion being formed of a sheet, the housing portion being formed in a folded state. Further, walls forming the housing portion include a first wall having a projection formed therefrom and a second wall having a hole formed therein, and the housing portion is formed by engagement between the first wall and the second wall through melting of the projection that has passed through the hole and welding of the melted projection to the second wall.