Wire Harness Cover Structure for Chipping Protection
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Solution Overview
Problem
Conventional wiring harnesses in vehicles are prone to chipping damage due to the lack of effective protection, especially when using corrugated tubes that are not fixed in position, and adhesive tapes which lose adhesiveness over time.
Innovation Solution
A wiring harness design featuring a cover member made of elastic materials like EPDM rubber that covers at least a portion of the cables and connectors, providing protection against chipping and misalignment, with clamping members to secure the cover in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If adhesive tape is used as exterior material, then the second wire group is protected, but more work is required to wind the adhesive tape and there is a risk of peeling due to decrease in adhesiveness over time
Solution Approach 1:
The patent uses a resinous exterior material that is extruded in a continuous form rather than wound adhesive tape. This disposable-like approach eliminates the need for winding operations and avoids adhesion degradation issues, while providing sufficient protection against chipping for the required service life.
Solution Approach 2:
The patent replaces the mechanical winding process of adhesive tape with an extrusion process. The resinous material is extruded continuously to form the exterior material, eliminating the manual or automated winding operation and associated complexity.
2Object-affected harmful factors
If corrugated tube is used as exterior material, then the second wire group is protected, but if the position of the corrugated tube is not fixed, there is a risk that the area prone to chipping cannot be properly protected
Solution Approach 1:
The patent merges the exterior material with the cable structure by having the resinous material extruded directly over the cables and connectors. This integration ensures the material remains in the correct position without requiring separate fixation mechanisms, while providing continuous protection against chipping.
Solution Approach 2:
The patent changes the physical state and application method of the exterior material from a pre-formed corrugated tube that requires positioning to a resinous material that is extruded in place. This parameter change eliminates positioning errors and ensures precise coverage of protection-needed areas.
3Object-affected harmful factors
If adhesive tape is used as exterior material, then the second wire group is protected, but there is a risk of peeling due to a decrease in adhesiveness over time
Solution Approach 1:
The patent uses a resinous exterior material that is extruded in a continuous form rather than wound adhesive tape. This disposable-like approach eliminates the need for winding operations and avoids adhesion degradation issues, while providing sufficient protection against chipping for the required service life.
Solution Approach 2:
The patent changes the physical state and application method of the exterior material from a pre-formed corrugated tube that requires positioning to a resinous material that is extruded in place. This parameter change eliminates positioning errors and ensures precise coverage of protection-needed areas.
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 effectively suppresses damage from chipping and misalignment, ensuring reliable protection of both trunk and branch cables, while reducing the risk of foreign matter entry and weight by optimizing the cover member's design.
Implementation Method 1
a cover member that covers at least a portion of the second cable together with a part of the one-side connector
Data Source
AI summary
A wiring harness includes a first cable and a second cable, a one-side connector arranged on one end of the first cable, and a cover member covering at least a portion of each of the first and second cables together with a portion of the one-side connector.