Wire Harness Overmold Structure for Friction-Free Assembly

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Solution Overview

Problem

In automotive applications, combining multiple wire assemblies into a single wire harness without the need for conventional stripping operations is challenging due to excessive friction holding the outer jacket onto the wire assembly, making it difficult to expose long segments for use.

Innovation Solution

A method involving a mold assembly with surface features to create an overmold structure, where individual wire assemblies are placed in the mold, and uncured material is injected to cure and join them, forming a wire harness with opposing ends free from the overmold, eliminating the need for stripping.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If wire assemblies are bundled into a single extrusion by the wire maker, then the wire harness structure is formed, but long segments of the wire assembly must be exposed which requires stripping the outer casing creating excessive friction

Engineering Contradiction:

Improveease of exposing wire assembliesVSAvoidfriction holding the main jacket onto the wire assembly

Core Design Contradiction:

Ease of manufactureVSForce

Solution Approach 1:

The patent divides the wire harness into segmented sections where individual wire assemblies are selectively exposed only at the specific locations where connections are needed. The overmold structure covers and protects the wire assemblies in non-connection areas, eliminating the need for long-striping operations and reducing friction-related manufacturing difficulties.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of stripping the outer casing to expose wire assemblies (conventional approach), the patent inverts the approach by using an overmold structure to cover and protect the wire assemblies, exposing them only where necessary through the molding process itself. This reversal eliminates the friction problem associated with long stripping operations.

Inventive Principle:

Principle #13The other way round (Inversion)

2Ease of operation

If stripping is used to expose wire assemblies, then the wire assemblies become accessible for connection, but the stripping distance becomes too long making stripping no longer a viable solution

Engineering Contradiction:

Improveaccessibility of wire assemblies for connectionVSAvoidcomplexity of stripping operation

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The overmold structure is formed in advance during the molding process, with the mold design pre-determining exactly where wire assemblies will be exposed and where they will be covered. This preliminary action eliminates the need for subsequent stripping operations to expose long segments of wire assemblies, simplifying the overall manufacturing process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces the mechanical stripping operation with a molding process. The overmold structure is formed by injecting material around the wire assemblies in the mold, which automatically exposes them only at the desired locations without requiring any stripping tools or operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If multiple wire assemblies are joined into a single wire harness, then the wire harness provides protection and ease of routing, but conventional joining methods require excessive stripping operations

Engineering Contradiction:

Improveprotection and routing capability of wire harnessVSAvoidmanufacturing complexity of joining wire assemblies

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines multiple wire assemblies into a single integrated wire harness structure using an overmold process. The overmold material unifies the multiple wires into one protected bundle while the mold design ensures that wire assemblies are exposed only at the specific connection points needed, eliminating excessive stripping operations and simplifying manufacturing.

Inventive Principle:

Principle #5Merging (Combining)

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

This approach effectively combines multiple wire assemblies into a single wire harness without stripping, providing flexibility, ease of routing, and protection, while allowing for custom configurations and reducing manufacturing complexity.

Implementation Method 1

During a molding process, uncured material is injected into the mold. The material is permitted to cure to define the overmold structure fixed to and joining the at least two wire assemblies.

Methodology Applied

Scientific EffectCuring: Phase Change

Data Source

PatentUS9527231B2Wire bundle overmold structure

Publication Date: 2016.12.27 CONTINENTAL AUTOMOTIVE SYSTEMS INC

AI summary

A method joins wire assemblies to define a wire harness by providing a mold assembly having a plurality of surface features therein to define an overmold structure. A portion of at least two individual and unconnected wire assemblies is placed into the mold assembly. The mold assembly is closed. During a molding process, uncured material is injected into the mold. The material is permitted to cure to define the overmold structure fixed to and joining the at least two wire assemblies. The portions of the wire assemblies are removed from the mold with the overmold structure thereon to define a wire harness, with opposing ends of the wire assemblies being free from covering by the overmold structure.