Integrated Wire Harness Protector for Impact Damping
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Solution Overview
Problem
Existing wire harnesses have multiple separate parts for the shell and protection members, which complicates assembly and increases costs.
Innovation Solution
A protector is designed with an integrally formed shell and protection portions made of resin, where the protection portion dampens impacts and is integrated with the shell, reducing the number of parts and improving assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the shell member and protection member are made as separate parts, then each part can be optimized for its specific function, but the number of parts increases and assembly complexity increases
Solution Approach 1:
The patent combines the shell member and protection member into a single integrated protector component. The shell portion and protection portion are formed as one piece through injection molding, eliminating the need for separate parts and assembly operations while maintaining both protective functions.
Solution Approach 2:
The integrated protector serves multiple functions simultaneously: the shell portion provides structural coverage and organization for electric wires, while the protection portion provides impact absorption. This multi-functional design eliminates the need for separate components.
2Ease of manufacture
If the shell member and protection member are made as separate parts, then manufacturing and assembly flexibility is maintained, but assembling workability deteriorates and time consumption increases
Solution Approach 1:
By merging the shell and protection members into a single integrated component, the assembly process is simplified to a single installation operation, dramatically improving assembling workability and reducing installation time.
Solution Approach 2:
The shell and protection portions are pre-integrated into a single molded component during manufacturing, so that no assembly operations are required during installation. This preliminary integration action eliminates assembly complexity.
3Adaptability or versatility
If the shell member and protection member are made as separate parts, then design flexibility is maintained, but manufacturing costs increase due to multiple parts and assembly operations
Solution Approach 1:
The integration of multiple functions into a single molded component reduces manufacturing costs by eliminating the need for multiple parts, inventory management, and assembly operations, while the molding process itself allows for design flexibility.
Solution Approach 2:
The injection molding process allows for easy modification of design parameters such as wall thickness, material composition, and geometric features, maintaining design flexibility while producing a cost-effective single-part solution.
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 integrated design reduces the number of parts, enhances assembly workability, and lowers manufacturing costs while effectively damping impacts on the electric wires.
Implementation Method 1
The protection portion dampens an impact applied from outside the protector
Data Source
AI summary
A protector includes a shell portion that is formed from a resin and covers an outer side of an electric wire and a protection portion that dampens an impact applied from outside the protector. The protection portion is formed from a resin and formed integrally with the shell portion.