Wire Harness Assembly With Selective Bonding Regions

Solution Overview

Problem

Conventional wire harness assemblies require a large amount of adhesive for bonding the cover to the base, leading to high manufacturing costs.

Innovation Solution

The wire harness assembly incorporates a wayside bonding portion along the electric wire, with non-bonding regions between the base and cover, reducing adhesive usage and integrating the components while maintaining the wire arrangement stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If bonding portion is provided on entire surface of assembly member, then bonding strength between base and cover is improved, but adhesive cost increases

Engineering Contradiction:

Improvebonding strengthVSAvoidadhesive quantity

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

The bonding portion is selectively provided only in regions where wire harnesses are arranged, rather than on the entire surface. This localizes the adhesive application to specific areas needed for securing the wire harnesses, reducing overall adhesive consumption while maintaining sufficient bonding strength in the critical regions.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The bonding portion is divided into multiple discrete bonding regions corresponding to different wire harness arrangement locations. Instead of a continuous full-surface bonding layer, the adhesive is applied in segmented portions at specific locations, which reduces the total adhesive quantity while ensuring each wire harness area is properly bonded.

Inventive Principle:

Principle #1Segmentation

2Stability of the object's composition

If bonding portion is provided on entire surface of assembly member, then wire harness arrangement stability is improved, but manufacturing cost increases

Engineering Contradiction:

Improvewire harness arrangement stabilityVSAvoidmanufacturing cost

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The bonding portion is selectively provided only in regions where wire harnesses are arranged, rather than on the entire surface. This localizes the adhesive application to specific areas needed for securing the wire harnesses, reducing overall adhesive consumption while maintaining sufficient bonding strength in the critical regions.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The bonding portion is divided into multiple discrete bonding regions corresponding to different wire harness arrangement locations. Instead of a continuous full-surface bonding layer, the adhesive is applied in segmented portions at specific locations, which reduces the total adhesive quantity and manufacturing cost while ensuring each wire harness area is properly bonded.

Inventive Principle:

Principle #1Segmentation

3Strength

If bonding portion is provided on entire surface of assembly member, then base and cover attachment is improved, but adhesive usage quantity increases

Engineering Contradiction:

Improveattachment strengthVSAvoidadhesive loss

Core Design Contradiction:

StrengthVSLoss of substance

Solution Approach 1:

The bonding portion is selectively provided only in regions where wire harnesses are arranged, rather than on the entire surface. This localizes the adhesive application to specific areas needed for securing the wire harnesses, reducing overall adhesive consumption while maintaining sufficient bonding strength in the critical regions.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The bonding portion is divided into multiple discrete bonding regions corresponding to different wire harness arrangement locations. Instead of a continuous full-surface bonding layer, the adhesive is applied in segmented portions at specific locations, which reduces the total adhesive quantity and prevents waste in areas where bonding is not required.

Inventive Principle:

Principle #1Segmentation

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 configuration reduces manufacturing costs by minimizing adhesive use and enhances assemblability, allowing easy fitting of connectors without adhesive interference.

Implementation Method 1

an adhesive is applied onto an entire surface of the bonding sheet to form a bonding portion, and the bonding sheet is attached to the soundproofing/heat insulating sheet via the bonding portion

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Data Source

PatentUS20250210222A1Wire harness assembly

Publication Date: 2025.06.26 YAZAKI CORP

AI summary

A wire harness assembly includes: a wire harness including an electric wire and a connector electrically connected to an end of the electric wire; and an assembly member in which the wire harness is arranged. The assembly member includes: a base; and a cover attached to the base via a bonding portion. The bonding portion includes a wayside bonding portion arranged along the electric wire. A non-bonding region in which the bonding portion is not arranged is provided between the base and the cover.