Wire Harness Holder With Bent Locking Extension
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Solution Overview
Problem
Conventional wire harnesses face issues where the fixing protrusion can come out of the through portion due to forces applied when the wire is wound around the holder, leading to separation of the holder from the cylindrical member.
Innovation Solution
The holder design includes a fixing portion with an outward extension that passes through the through portion and a bent extension, which reduces the likelihood of the fixing portion coming out, and a claw portion that fits into a recessed portion on the cylindrical member to restrict movement, preventing separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple fixing protrusion is used to attach the holder to the cylindrical member, then the device complexity is reduced and manufacturing is easier, but the reliability of the attachment deteriorates as the fixing protrusion may come out of the through portion under force
Solution Approach 1:
The fixing portion incorporates a bent extension that curves at a predetermined angle instead of using a simple straight protrusion. This curved geometry provides mechanical advantage by creating a hook-like structure that engages with the through portion, making it resistant to extraction forces while maintaining manufacturing simplicity through single-piece molding.
Solution Approach 2:
The fixing portion extends not only radially outward through the through portion but also includes a bent extension that projects in a direction oblique to the radial direction. This multi-dimensional configuration creates a more secure engagement by distributing the holding force across multiple spatial dimensions, preventing the fixing portion from being pulled out.
2Reliability
If the fixing portion is made longer and more complex to prevent separation, then the attachment reliability improves, but the ease of manufacture deteriorates due to more complex through portion shapes required
Solution Approach 1:
The bent extension uses a smooth curved geometry that can be formed using standard molding techniques. The curvature radius is designed to be between 0.5mm and 5mm, which is within the capability of conventional injection molding processes, thus maintaining ease of manufacture while achieving reliable attachment.
Solution Approach 2:
The design specifies that the bending angle of the bent extension should be between 30 degrees and 150 degrees, and the curvature radius between 0.5mm and 5mm. These parameter ranges optimize both the attachment reliability and manufacturability, ensuring the bent extension provides sufficient mechanical engagement without being so complex as to require specialized manufacturing processes.
3Ease of operation
If a straight fixing protrusion is used, then the ease of operation is improved during assembly, but the stability of the attachment deteriorates as the fixing protrusion can come out under force from wire winding
Solution Approach 1:
The bent extension creates a hook-like structure that naturally resists forces applied in the radial direction. When the holder is assembled, the bent extension flexes to pass through the through portion and then locks into place, providing intuitive feedback to the operator. The same curved geometry that provides stability also maintains ease of assembly through its flexible installation process.
Data Source
AI summary
A holder including: an inner fitting that is configured to be fitted into a longitudinal end of a cylinder that covers an outer circumference of a wire; a holding piece that protrudes from the inner fitting outward of the longitudinal end of the cylinder, and is configured to hold the wire; and a fixing portion that protrudes radially outward from the inner fitting, wherein the fixing portion includes: an outward extension that protrudes radially outward from the inner fitting and is configured to pass through a through portion provided in the cylinder; and a bent extension that bends and extends from a leading end of the outward extension.