Wire Harness Protector Triple Wall Coupling Strength
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Solution Overview
Problem
The coupling site of existing connecting type protectors for wire harnesses has low strength and is prone to deformation under longitudinal or lateral loads, leading to potential damage from interference with other vehicle components.
Innovation Solution
A protector design featuring first and second resin molding members with U-shaped configurations, including a double wall structure with a cover section and a through-hole, forming a triple wall structure when connected, which enhances strength and resistance to deformation by concentrating stress at opposite corners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the protector is divided into multiple segments to mold individually and assemble, then the manufacturing flexibility and adaptability to complicated bent configurations is improved, but the coupling site strength deteriorates and deformation resistance worsens
Solution Approach 1:
The second coupling portion is inserted into the clearance between the inner wall section and cover section of the first coupling portion, creating a nested structure where one coupling portion is partially contained within another. This nesting arrangement significantly enhances coupling site strength while maintaining the segmented design flexibility needed for complicated bent configurations.
Solution Approach 2:
The invention transitions from a single-wall coupling structure to a triple wall structure by adding the cover section that creates a clearance dimension. This dimensional change allows the second coupling portion to be inserted and secured in three-dimensional space, providing superior strength and deformation resistance compared to conventional single-plane coupling methods.
2Ease of operation
If the coupling site structure is simplified for ease of assembly, then the ease of operation is improved, but the strength and deformation resistance of the coupling site deteriorates
Solution Approach 1:
The protrusion on the second coupling portion automatically engages with the through-hole in the first coupling portion during insertion, creating self-positioning and self-locking functionality. This self-service mechanism ensures proper alignment and secure coupling without requiring additional locking operations or complex assembly procedures, maintaining ease of operation while achieving high strength.
3Strength
If additional locking mechanisms are added to enhance coupling site strength, then the strength and deformation resistance is improved, but the device complexity increases
Solution Approach 1:
The invention merges the coupling, positioning, and locking functions into a single integrated structure. The clearance between the inner wall section and cover section serves as both the insertion path and the locking chamber, while the protrusion and through-hole combination provides both positioning and mechanical interlocking. This merging eliminates the need for separate locking mechanisms, reducing device complexity while maintaining high strength.
Data Source
AI summary
A first coupling of a first protector includes a U-shaped inner wall section and a cover. The inner wall section has an inner bottom wall and opposed inner side walls. The cover extends from outer surfaces of the inner bottom wall and opposed inner side walls of the inner wall section to a distal end opening in the first coupling. The cover is open at a distal end. A second coupling of a second protector includes a bottom wall and opposed side walls that are inserted through the distal end opening into a clearance defined between the inner wall section and the cover of the first protector. The first and second couplings of the first and second protectors are connected together so that the second coupling of the second protector is caught between the inner wall and the cover of the first coupling of the first protector.