Thermoplastic Adhesive Wire Harness Fixing to Roof Liner
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Solution Overview
Problem
Existing methods for fixing a wire harness to an automobile's roof liner are inefficient, requiring time-consuming and labor-intensive processes, and often result in uncertain fixation due to non-uniform wire shapes and the need for specialized equipment or complex procedures.
Innovation Solution
A method involving a sheet material coated with thermoplastic adhesive, where the wire harness is covered and pressed onto the roof liner, utilizing the adhesive's warmth to generate adhesiveness and secure the harness without the need for extensive equipment or complex operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If double-side adhesive tape is used to fix the wire harness to the roof liner, then the wire harness can be fixed without specialized equipment, but the fixing is uncertain due to non-uniform wire shape and insufficient bonding surface
Solution Approach 1:
The wire harness is segmented into multiple individual wires rather than treated as a single bundled unit. Each wire is independently bonded to the roof liner, ensuring that the bonding surface is distributed across multiple contact points. This segmentation allows the non-uniform wire shapes to be individually accommodated while maintaining overall fixing reliability.
Solution Approach 2:
Different portions of the wire harness are bonded at different locations along the roof liner. The bonding is applied locally at multiple discrete points rather than requiring a continuous uniform bonding surface. This local quality approach allows each wire segment to be bonded optimally at its specific location, compensating for shape variations.
2Reliability
If multiple unbundled electric wires are enclosed with a flexible sheet and bonded, then the bonding surface is increased, but the process becomes time-consuming and labor-intensive
Solution Approach 1:
The wire harness is pre-assembled and positioned in its final configuration before bonding. The wires are arranged in their intended wiring path, and then the bonding process is applied. This preliminary positioning eliminates the need for time-consuming adjustments during the bonding process itself, reducing assembly time while maintaining fixing reliability.
Solution Approach 2:
The wire harness structure itself provides the bonding surface through its outer insulation layer. Each wire's insulation serves as its own bonding interface with the roof liner, eliminating the need for additional flexible sheets or intermediary bonding materials. This self-service approach reduces material handling time while ensuring reliable bonding.
3Ease of manufacture
If terminal portion and ear piece are tied with adhesive tape, then peripheral fixation is achieved, but the wire harness is not fixed certainly along the wiring path
Solution Approach 1:
The bonding action is applied continuously along the entire wiring path of the wire harness, rather than only at discrete locations such as the terminal portion and ear piece. This continuous bonding ensures that the wire harness is fixed at every point along its path, preventing movement and vibration while maintaining process simplicity through a unified bonding operation.
4Strength
If melted resin is poured between roof liner and wire harness, then strong bonding is achieved, but large-scale dedicated equipment is required
Solution Approach 1:
The complex thermal processing system involving melted resin pouring is replaced with a simpler adhesive bonding system. Instead of requiring large-scale equipment to melt and pour resin, a pre-formed adhesive layer is applied to the roof liner, and the wire harness is pressed onto it. This substitution maintains strong bonding while eliminating the need for complex dedicated equipment.
Solution Approach 2:
A disposable adhesive layer is applied to the roof liner instead of using a reusable melted resin system. The adhesive is applied once, the wire harness is bonded, and the process is complete. This eliminates the need for expensive, complex equipment required to melt and manage resin, while achieving sufficient bonding strength for the application.
5Reliability
If sheet material is wound around wire harness and then expanded and welded, then fixation is achieved, but the process takes time and effort
Solution Approach 1:
The adhesive layer is pre-applied to the sheet material before the wire harness is positioned. This preliminary preparation eliminates the need for time-consuming winding, expanding, and welding operations. The wire harness is simply pressed onto the pre-adhered sheet material, achieving stable fixation in a single rapid operation.
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 method simplifies the assembly process, ensures stable and certain fixation of the wire harness, reduces operational time, and eliminates the need for specialized structures or equipment, while maintaining a conforming shape to the wiring path.
Implementation Method 1
a sheet material 12 in which a thermoplastic adhesive is coated on one surface including a required portion so as to fix the wire harness to the sheet material
Implementation Method 2
fixing the wire harness structure to the roof liner with the thermoplastic adhesive by pressurizing the required portion warmed
Data Source
AI summary
A fixing method of a wire harness is provided. A wire harness structure is formed by covering a wire harness with a sheet material in which a thermoplastic adhesive is coated on one surface including a required portion so as to fix the wire harness to the sheet material. The formed wire harness structure is spread on a roof liner. By pressuring the required portion warmed, the wire harness structure is fixed to the roof liner with the thermoplastic adhesive.