Wire Harness Connection Structure for Controlled Collision Severance
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Solution Overview
Problem
Conventional wire harness connection structures face issues with high contact resistance due to small contact areas between electric wires, leading to increased weight and complexity, especially in high-voltage and high-current applications, and lack of predictability in wire severance during vehicle collisions.
Innovation Solution
A connection structure for wire harnesses that uses fusing-processed extension and protruding portions with tapered and concave shapes to enhance contact area and allow for controlled separation under tension, reducing weight and improving severability during collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the diameters of the two electric wires are increased to increase the connection area of the end faces, then the contact area is increased, but the overall weight of the wire harness increases
Solution Approach 1:
The invention transitions from face-to-face contact (2D contact area) to line contact through the tapered portion inserted in the concave portion (1D contact line extended along the axial direction). This dimensional change allows sufficient contact area without increasing wire diameter, thereby avoiding weight increase.
Solution Approach 2:
The invention changes the contact geometry parameters by creating a tapered portion with specific angle and a corresponding concave portion, transforming the contact mode from face contact to tapered line contact. This parameter optimization achieves adequate contact area with smaller wire dimensions, reducing weight.
2Area of stationary object
If the contact area is increased by using socket contact with hyperbolic grid shape, then the contact area is increased, but the structure becomes more complicated and the connection structure becomes larger in size
Solution Approach 1:
The invention extracts only the essential functional feature of increased contact area from the complex socket contact structure, simplifying it to a tapered portion and concave portion configuration. This extraction maintains the contact area benefit while eliminating the hyperbolic grid complexity.
Solution Approach 2:
Instead of creating a complex protruding socket contact structure, the invention inverts the approach by creating a concave portion in one wire and a tapered portion in the other, achieving contact through insertion rather than through complex grid engagement.
3Device complexity
If the end faces of the two electric wires are merely butted against each other, then the structure is simple, but the contact is uncertain due to unevenness of the end surfaces and the contact area is small
Solution Approach 1:
The invention applies preliminary action by pre-forming the tapered portion and concave portion geometries before connection. This preliminary shaping ensures that when the wires are connected, the tapered portion naturally guides into the concave portion, compensating for end face unevenness and ensuring reliable contact.
Solution Approach 2:
The tapered portion acts as an intermediary element between the two wire conductors. Instead of relying on direct face-to-face contact, the tapered portion inserted in the concave portion mediates the connection, ensuring reliable electrical contact despite variations in end face flatness.
4Power
If larger diameter conductors are used to handle high voltage and large current, then the current carrying capacity is increased, but the size and weight of wire harnesses increase
Solution Approach 1:
The invention addresses the current carrying capacity issue by optimizing the connection geometry (tapered line contact) rather than increasing conductor diameter. This allows maintaining adequate power handling through improved connection efficiency without the weight penalty of larger conductors.
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
The solution provides a reliable and lightweight connection with increased contact area for efficient current flow and controlled severance, reducing the risk of conductor exposure and weight increase, while allowing for predictable wire harness severance during vehicle collisions.
Implementation Method 1
the first connection end portion and the second connection end portion are integrally connected to each other by crimping the first extension portion and the second extension portion from a radial-direction outer side by the connecting member
Implementation Method 2
end portions of the first electric wire and the second electric wire are respectively provided with a first connection end portion and a second connection end portion in which conductors of the end portions have been subjected to fusing processing
Data Source
AI summary
A connection structure of a wire harness enables the wire harness to be severed in the event of a vehicle collision. End portions of electric wires are respectively provided with connection end portions in which conductors of the end portions have been subjected to fusing processing, the connection end portion has an extension portion and a protruding portion, the protruding portion is at least partially provided with a tapered portion, the connection end portions are integrally connected to each other by crimping the extension portions from the radial-direction outer side by the connecting member, and at the connection end portion, the crimping of an extension portion to press the tapered portion inserted in a concave portion causes the engagement force between the extension portion and the connecting member to become weaker than the engagement force between the extension portion and the connecting member when applying tension to the electric wires.