Wire Harness Sheath with Variable Rigidity
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Solution Overview
Problem
Conventional wire harnesses require post-attached exterior members for route restriction, increasing component count, cost, and manufacturing workload, but excluding these members compromises route restriction.
Innovation Solution
A wire harness design featuring conductive paths with varying sheath thickness and rigidity, where thicker, rigid sheath parts provide route restriction without external members, and continuous, tapered connections reduce manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If post-attached exterior members are used for route restriction, then route restriction is achieved, but the number of components increases and cost increases
Solution Approach 1:
The patent merges the exterior member function into the sheath itself by creating a multi-layer structure where the first sheath part (thicker, rigid) provides route restriction while the second sheath part (thinner, flexible) provides flexibility. This integration eliminates the need for separate post-attached exterior members, reducing component count while maintaining route restriction capability.
Solution Approach 2:
The patent applies local quality by varying the sheath thickness and rigidity along its length. The first sheath part has greater thickness and rigidity for route restriction sections, while the second sheath part has reduced thickness for flexibility sections. This localized differentiation allows the sheath to perform multiple functions without requiring additional components.
2Reliability
If post-attached exterior members are used for route restriction, then route restriction is achieved, but manufacturing workload increases
Solution Approach 1:
The patent incorporates the route restriction function directly into the sheath structure during the initial manufacturing process. The multi-layer sheath is formed with predetermined thickness variations that provide rigid sections for route restriction before the wire harness assembly begins, eliminating the need for post-assembly attachment of exterior members and reducing manufacturing workload.
3Ease of manufacture
If the sheath is made uniformly thick, then manufacturing is simplified, but route restriction capability is lost
Solution Approach 1:
The patent resolves this contradiction by implementing local quality through a multi-layer sheath structure. The first sheath part has greater thickness for route restriction sections, while the second sheath part has reduced thickness for flexibility sections. This localized differentiation allows the sheath to provide route restriction capability where needed while maintaining manufacturing feasibility through a systematic multi-layer construction approach.
Data Source
AI summary
A wire harness includes a conductive path. The conductive path includes a conductor and a sheath that covers the conductor. The sheath includes a first sheath part arranged correspondingly to a route restriction section where route restriction is required and a second sheath part arranged correspondingly to a different section other than the route restriction section. The first sheath part is formed thicker than the second sheath part, and the first sheath part has rigidity.