Wire Harness Self-Adhesive Sheet Winding Method

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The existing wire harness manufacturing methods are inefficient due to the need for cutting and applying adhesive layers to specific portions of sheets, which reduces manufacturing efficiency and requires additional time and labor.

Innovation Solution

A method involving sheets with self-adhesive layers on one entire surface, where the first sheet is wound on cables with its non-self-adhesive layer inside and the second sheet is wound on the intermediate member with its self-adhesive layer inside, allowing for efficient bundling without the need for forming special sheets or precise positioning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a sheet with self-adhesive layers on only specific portions is used, then cables can be bundled with proper positioning, but manufacturing efficiency decreases due to cutting and applying adhesive layers to specific portions

Engineering Contradiction:

Improvepositioning precisionVSAvoidmanufacturing efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The sheet is divided into a self-adhesive layer and a non-self-adhesive layer, with the self-adhesive layer applied only to specific portions (first and second portions) of the sheet. This segmentation allows the sheet to provide positioning precision where needed while maintaining manufacturing efficiency by using a standardized sheet structure that can be produced in rolls.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The sheet has different properties in different regions: the first and second portions have self-adhesive layers for bonding to cables, while the third portion has no adhesive layer for easy positioning and handling. This local quality differentiation enables both precise cable bundling and efficient manufacturing without requiring cutting or adhesive application during the bundling process.

Inventive Principle:

Principle #3Local quality

2Strength

If a sheet with self-adhesive layers on both surfaces is used, then bonding strength is improved, but the sheet cannot be properly positioned and handled during bundling

Engineering Contradiction:

Improvebonding strengthVSAvoidpositioning ease

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If sheets are cut to specific sizes for each bundling operation, then proper fit is achieved, but additional time and labor are required

Engineering Contradiction:

Improvesheet size precisionVSAvoidpreparation time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The sheet is pre-designed with clearly defined first, second, and third portions, where the first and second portions have self-adhesive layers and the third portion has no adhesive layer. This preliminary design allows workers to quickly identify and position the correct sheet portions without requiring cutting or measurement, significantly reducing preparation time while maintaining proper fit.

Inventive Principle:

Principle #10Preliminary action

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 enhances manufacturing efficiency by eliminating the need for forming special sheets and reduces labor, ensuring proper bundling of cables even if the sheets are shorter than the cable circumference, while preventing cable separation during the bundling process.

Implementation Method 1

The self-adhesive layer is an adhesive layer that adheres to and therefore fixes to another self-adhesive layer

Methodology Applied

Scientific EffectAdhesive: Adhesive

Data Source

PatentUS9530538B2Wire harness manufacturing method and wire harness

Publication Date: 2016.12.27 YAZAKI CORP

AI summary

A wire harness includes plural cables, a first sheet and a second sheet. The first sheet includes a base sheet, and a self-adhesive layer formed on a whole of only first surface of the base sheet. The first sheet is wound on the plural cables so that a non-self-adhesive layer formed on a second surface, opposite to the first surface, of the first sheet is located inside. The second sheet includes a base sheet and a self-adhesive layer formed on a whole of only first surface of the base sheet. The second sheet is wound on the first sheet so that the self-adhesive layer of the first surface of the second sheet is located inside.