Wire Harness Connector Separator for Water-Blocking
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Solution Overview
Problem
The existing wire harnesses face issues with impaired water-blocking properties due to the breakage of heat shrinkable tubes when press-fitted over the edges of ultrasonic-welded connection portions between single-core and twisted wires, leading to compromised sealing and potential separation under bending stress.
Innovation Solution
Incorporating a separator, such as a tubular member or metal plate, between the connection ends of the wires and the heat shrinkable tube to prevent direct contact and pressure on the edges, ensuring the heat shrinkable tube is not press-fitted to the edges, thereby maintaining the water-blocking properties and distributing bending stress effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the heat shrinkable tube is directly press-fitted over the edges of the ultrasonic-welded connection portion, then the water-blocking properties are improved by ensuring tight sealing, but the heat shrinkable tube may break due to pressure on the sharp edges
Solution Approach 1:
A separator (tubular member or metal plate) is introduced as an intermediary component between the heat shrinkable tube and the sharp edges of the ultrasonic-welded connection portion. The separator covers the sharp edges and distributes the pressing force, preventing the heat shrinkable tube from breaking while maintaining tight sealing contact with the separator surface, thus ensuring both water-blocking properties and tube integrity.
2Strength
If the single-core wire is beaten down into a flat plate shape for ultrasonic welding, then the welding strength between single-core wire and twisted wires is improved, but sharp edges are formed that can cause heat shrinkable tube breakage
Solution Approach 1:
The separator serves as a protective intermediary that covers the sharp edges formed during the ultrasonic welding process. By placing the separator over the welded connection portion before applying the heat shrinkable tube, the sharp edges are neutralized and cannot cause tube breakage, while the welding strength is preserved through the ultrasonic welding process itself.
Solution Approach 2:
The separator is installed beforehand to cushion and distribute the pressure that will be applied during the heat shrinking process. This prior protection prevents the heat shrinkable tube from breaking when pressed against the sharp edges, allowing the welding strength to be fully realized without the harmful effect of edge concentration.
3Reliability
If the heat shrinkable tube is made to tightly cover the connection portion for water blocking, then the sealing performance is improved, but bending stress concentrates at the connection portion causing potential separation
Solution Approach 1:
The separator acts as a stress-distributing intermediary between the heat shrinkable tube and the wire connection portion. When bending stress is applied, the separator's larger surface area distributes the stress across a wider region, preventing stress concentration at the vulnerable connection point and reducing the risk of separation, while still maintaining sealing performance through contact with the separator.
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 enhances the water-blocking properties of the connection portion and prevents damage to the heat shrinkable tube, ensuring reliable sealing and improved durability against bending stress.
Implementation Method 1
the heat shrinkable tube 7 is heated so as to shrink
Implementation Method 2
the single-core wire 5 and the twisted wires 6 are ultrasonic-welded to each other
Data Source
AI summary
A wire harness that includes a connector in which a connection end of a single-core wire electrical cable and a connection end of a twisted wire electrical cable are welded to each other and are covered by a heat shrinkable tube, wherein the connector includes a separator between the connection end of the twisted wire electrical cable and the heat shrinkable tube, the separator being made of metal and being configured to separate the connection end of the twisted wire electrical cable from the heat shrinkable tube.