Flexible-Board Wire Harness for Automated Joint Integration
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Solution Overview
Problem
Conventional wire harnesses face challenges in manufacturability, particularly in automating the manufacturing of joint units that electrically connect conductors, making them difficult to produce efficiently.
Innovation Solution
A wire harness design incorporating an electric wire module with a connector and a flexible board module, where the flexible board includes a wiring unit with a joint unit that connects multiple wires, allowing for automated manufacturing by eliminating the need for separate joint units and enabling compact integration of transmission lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a conventional wire harness with separate joint units is used, then the electrical connection between conductors is achieved, but the manufacturing automation is difficult and production efficiency is low
Solution Approach 1:
The patent merges the joint unit functionality into the flexible board itself. The flexible board includes conductive patterns that directly connect to multiple electric wires, eliminating the need for separate joint units. This integration allows the wiring unit to perform both connection and joint functions through a single component, enabling automated manufacturing processes.
Solution Approach 2:
The flexible board serves multiple functions: it provides electrical connection between wires, acts as a joint unit for multiple conductors, and enables routing flexibility. By making the flexible board multi-functional, the patent eliminates the need for separate specialized components, thereby improving manufacturing automation and productivity.
2Reliability
If multiple separate joint units are used to connect conductors, then electrical connectivity is achieved, but the device complexity increases and manufacturing becomes more difficult
Solution Approach 1:
The patent combines multiple joint unit functions into a single flexible board structure. The flexible board's conductive patterns create multiple connection points that simultaneously connect to various electric wires, reducing the number of separate components while maintaining reliable electrical connectivity.
Solution Approach 2:
The flexible board uses uniform conductive patterns and materials throughout its structure to create consistent electrical connections. This homogeneity in design and material usage simplifies the overall device structure while ensuring reliable connectivity across all connection points.
3Reliability
If traditional wire harness construction is used, then electrical connections are established, but the manufacturing cost is high due to multiple components
Solution Approach 1:
The patent reduces manufacturing costs by merging multiple components (separate joint units and wiring elements) into a single integrated flexible board. This reduction in component count directly lowers material costs, assembly costs, and inventory requirements while maintaining reliable electrical connections.
Solution Approach 2:
The flexible board performs multiple functions (connection, joint, routing) that previously required separate specialized components. This multi-functionality reduces the total bill of materials and simplifies manufacturing processes, thereby reducing overall manufacturing cost while ensuring reliable electrical connections.
Data Source
AI summary
A wire harness includes an electric wire module including a plurality of electric wires and an electric wire-side connector provided at an end portion of the plurality of electric wires, and a board module including a flexible board, a first board-side connector provided at one end portion of the flexible board and connected to the electric wire-side connector, and a second board-side connector provided at the other end portion of the flexible board and connected to a connector of a control unit. The flexible board includes a wiring unit having a plurality of wires electrically connected to each of the plurality of electric wires via the electric wire-side connector and the first board-side connector. The wiring unit includes a joint unit that connects at least two of the plurality of wires to each other.