Wire Harness Fixing Structure With Flat-Surface Bonding
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Solution Overview
Problem
Existing methods for attaching and fixing wire harnesses to molded ceilings often result in insufficient adhesion strength, particularly with thick or heavy wire bundles.
Innovation Solution
A fixing structure for a wiring member that includes an electrical wire bundle, an exterior member with a flat outer surface, and an adherend with a flat main surface, where the surfaces are bonded using an adhesive member or a welding layer that melts upon heat application, ensuring a firm bond between the wire bundle and the adherend.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a double-sided adhesive tape is used to attach the wire harness to the molded ceiling, then the attachment process is simple, but the adhesion strength is insufficient when the wire harness is thick or heavy
Solution Approach 1:
The solution segments the attachment function into two parts: the exterior member provides mechanical support and structural strength for thick/heavy wire bundles, while the adhesive tape provides the bonding function. This segmentation allows each component to optimize its function without compromise.
Solution Approach 2:
The exterior member acts as an intermediary between the wire bundle and the adhesive tape. It transfers the load from the heavy wire bundle to the adhesive tape, distributing the stress and preventing direct attachment failures that would occur with thick bundles alone.
2Quantity of substance
If the wire bundle is made thick to accommodate more wires, then the electrical capacity increases, but the adhesion strength decreases
Solution Approach 1:
The exterior member separates the electrical function (handled by the wire bundle thickness) from the mechanical attachment function (handled by the exterior member and adhesive). This allows the wire bundle to be as thick as needed for electrical capacity without compromising attachment strength.
Solution Approach 2:
The attachment system uses a composite structure combining the exterior member (providing mechanical strength) with the adhesive tape (providing bonding). This composite approach allows thick wire bundles to be securely attached by distributing the mechanical load across both materials.
3Reliability
If additional fixing members are used to improve adhesion strength, then the bonding reliability increases, but the device complexity increases
Solution Approach 1:
The exterior member serves multiple functions simultaneously: it provides mechanical support for thick wire bundles, creates a flat bonding surface for the adhesive tape, and distributes the attachment load. This multi-functionality achieves reliable bonding without adding separate fixing components.
Solution Approach 2:
The solution merges the structural support function and the attachment function into a single integrated system (exterior member + adhesive tape combination), eliminating the need for separate fixing members like clips, screws, or additional fasteners.
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 strong and reliable bonding of the electrical wire bundle to the adherend, maintaining adhesion even when the welding layer is exposed before bonding, and reduces the need for additional fixing members.
Implementation Method 1
the adhesive member includes a welding layer which is melted when heat is applied and can be bonded
Implementation Method 2
the welding layer is melted when heat is applied
Data Source
AI summary
A fixing structure of a wiring member includes: an electrical wire bundle; an exterior member externally mounted to the electrical wire bundle; and an adherend having a main surface as a flat surface, wherein the exterior member has an outer surface as a flat surface, and the outer surface and the main surface have surface contact with and are bonded to each other while the electrical wire bundle is disposed on the main surface of the adherend.