Integrated Wire Harness Protector with Variable Wall Thickness

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Solution Overview

Problem

Conventional wire harnesses for vehicles require a multitude of exterior members with different functions, leading to increased part counts, overlapping components, and higher mounting costs due to complex routing structures.

Innovation Solution

A harness exterior protection member formed from a flame-retardant polyamide resin composition, integrating a cylindrical bent portion and a thicker cylindrical straight portion, reducing the number of parts and mounting man-hours by aggregating functions, with specific thickness and bending strength specifications.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple exterior members with different functions are used for wire harness routing, then the wire harness can be routed along the vehicle body panel, but the number of parts increases and mounting cost increases

Engineering Contradiction:

Improverouting capabilityVSAvoidnumber of parts

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines multiple exterior members (corrugated tube, hard tube, protector) into a single integrated exterior protection member. This unified structure performs all necessary functions including bending at routing points and providing protection at straight sections, thereby reducing the number of parts while maintaining routing adaptability

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The exterior protection member is designed to perform multiple functions simultaneously: it provides flexibility at bent portions for routing along the vehicle body panel, while also providing protection at straight portions. This multi-functional design eliminates the need for separate specialized components

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If multiple exterior members are used for wire harness routing, then the wire harness can be protected and routed, but mounting time increases

Engineering Contradiction:

ImproveprotectionVSAvoidmounting time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

By merging multiple protection and routing functions into a single exterior protection member, the mounting process is simplified. Instead of installing multiple separate components, the unified structure can be installed as one piece, significantly reducing mounting time while maintaining the same level of protection

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If exterior members overlap in the routing structure, then the wire harness is protected, but cost increases due to overlapping components

Engineering Contradiction:

ImproveprotectionVSAvoidmaterial cost

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The integrated exterior protection member consolidates overlapping protection functions into a single structure, eliminating redundant materials. The unified design provides necessary protection without the excess material usage that results from stacking multiple separate protective components

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS9627104B2Harness exterior protection member and wire harness using the same

Publication Date: 2017.04.18 YAZAKI CORP

AI summary

A harness exterior protection member with an electric wire bundle inserted therein includes a bent portion and a straight portion which are formed in a cylindrical shape in an integrated manner formed of a flame-retardant polyamide resin composition. A thickness of the straight portion is set to be twice to four times of a thickness of the bent portion. A bending radius of the bent portion is 10 mm or larger, and a bending strength of the straight portion is 15 to 25 N.