Shielded Wire Harness Connection Layout for Smaller Cross-Sections
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Solution Overview
Problem
The overlap of single-core and stranded wires at the connection portion in conventional wire harnesses increases the cross-sectional size, necessitating a larger shield pipe diameter, which in turn enlarges the entire wire harness.
Innovation Solution
A wire harness design featuring a first tubular member with a protrusion and a second tubular member that covers the connection portion externally, allowing the connection to be positioned longitudinally, thereby maintaining a smaller inner diameter of the first tubular member and reducing the overall harness size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the single-core wire and stranded wire overlap each other at the connection portion, then reliable electrical connection is achieved, but the cross-sectional size of the connection portion increases
Solution Approach 1:
The patent transitions the wire connection from a transverse overlap configuration to a longitudinal end-to-end configuration. Instead of overlapping wires side-by-side (increasing cross-sectional area), the wires are connected end-to-end along the longitudinal axis, maintaining a compact cross-section while achieving reliable electrical connection through soldering or welding at the joined ends.
Solution Approach 2:
The patent divides the connection structure into distinct segments: a first tube covering the single-core wire, a second tube covering the stranded wire, and a connection portion joining these tubes. This segmentation allows each component to be optimized independently - the tubes provide protection and positioning while the connection portion achieves reliable electrical contact without increasing overall cross-sectional dimensions.
2Reliability
If the shield pipe inner diameter is increased to accommodate the enlarged connection portion, then the connection is properly covered, but the outer diameter of the shield pipe increases
Solution Approach 1:
By changing the connection configuration from transverse overlap to longitudinal end-to-end joining, the patent eliminates the need to increase the shield pipe's cross-sectional dimensions. The connection portion fits within the existing shield pipe inner diameter, maintaining a compact outer diameter while ensuring proper coverage through the tubular structure.
3Length of stationary object
If the first tube inner diameter is reduced to maintain smaller harness size, then overall size is reduced, but the drawn-out portion needs precise positioning
Solution Approach 1:
The patent introduces the second tube as an intermediary component that receives and positions the drawn-out portion of the single-core wire. This second tube acts as a mediator between the first tube and the connection portion, providing a receptacle that ensures precise positioning without requiring the first tube to have a larger inner diameter, thus maintaining compact harness dimensions.
Solution Approach 2:
By segmenting the protective structure into two separate tubes - the first tube for the single-core wire and the second tube for the stranded wire and connection portion - the patent enables each tube to be optimized for its specific function. The first tube can have a smaller inner diameter while the second tube provides the necessary positioning space for the drawn-out portion.
Data Source
AI summary
A wire harness that includes an electric wire; a first tube that is made of a metal and covers an outer circumference of the electric wire; a braided wire that is formed by braiding conductive strands into a tubular shape, is attached to an outer circumferential surface of the first tube, and covers an outer circumference of a drawn-out portion of the electric wire, the drawn-out portion being drawn out from an end of the first tube; and a second tube that is made of a metal.