Wire Harness Unit Galvanic Corrosion Prevention via Rubber Insulation
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Solution Overview
Problem
Galvanic corrosion occurs between metal components of different metals in wire harnesses, particularly between metal pipes and clips used in vehicle harnesses, leading to reliability issues.
Innovation Solution
A wire harness unit design that includes a metal tubular member covered by a rubber member, which prevents direct contact between the metal tubular member and a bracket made of a different metal, thereby preventing corrosion. The design uses fastening members to secure the rubber member and the tubular member, ensuring electrical insulation and mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal pipe and a clip made of different metals are used to fix the harness, then the fastening strength is improved, but galvanic corrosion occurs between the different metals
Solution Approach 1:
A rubber member is introduced as an intermediary between the metal pipe and the clip. This rubber member prevents direct contact between the two different metals, thereby eliminating the galvanic corrosion pathway while allowing the clip to maintain its fastening function on the metal pipe.
Solution Approach 2:
The rubber member functions as a flexible protective shell that wraps around or is positioned between the metal pipe and clip. This flexible barrier provides both corrosion protection and allows for some mechanical flexibility in the fastening assembly.
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 solution effectively suppresses galvanic corrosion, ensuring the reliability and longevity of the wire harness by maintaining the metals in a non-contact state, while also providing secure fastening and support for the tubular members.
Implementation Method 1
The first fixing portion supports the first tubular member with the rubber member in between. The first tubular member is made of a metal that contains a first metal as a major component. The bracket is made of a metal that contains a second metal, which is different from the first metal, as a major component.
Data Source
AI summary
A wire harness unit includes a first electrical cable, a first tubular member that covers the first electrical cable, a rubber member that is attached to an outer circumferential surface of the first tubular member, a bracket that includes a first fixing portion supporting the first tubular member with the rubber member in between, and a fastening member that surrounds and fastens the rubber member and the first fixing portion. The first tubular member is made of a metal that contains a first metal as a major component. The bracket is made of a metal that contains a second metal, which is different from the first metal, as a major component.