Wire Harness Sheet Member Vibration Damage Prevention

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Solution Overview

Problem

In wire harnesses for hybrid motor vehicles, the electrically conductive paths within tubular sheath members are prone to damage due to vibration, which causes them to rub against the sheath and leads to abrasion and potential breakage, exacerbated by dust and sand accumulation over time.

Innovation Solution

A wire harness design that incorporates a sheet member positioned between the electrically conductive paths and the inner peripheral surface of the sheath member, either wound to cover the entire circumferential area or intermittently arranged in the axial direction, to prevent direct contact and movement-induced damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the inner space of the sheath member is designed with a margin to allow insertion of the electrically conductive path, then the ease of insertion is improved, but the electrically conductive path sways and rubs against the sheath member due to vibration, leading to damage

Engineering Contradiction:

Improveease of insertionVSAvoiddamage resistance of electrically conductive path

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

A sheet member is introduced as an intermediary component between the electrically conductive path and the inner peripheral surface of the sheath member. This sheet member fills the clearance space, preventing direct contact between the conductive path and sheath member, thereby eliminating the rubbing and damage caused by vibration while still allowing easy insertion during assembly

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The sheet member is designed as a flexible thin film that can conform to the inner space of the sheath member. This flexible structure allows the sheet to adapt to the geometry of the sheath member and electrically conductive path, providing continuous protection against rubbing while maintaining the overall flexibility and ease of assembly of the wire harness

Inventive Principle:

Principle #30Flexible shells and thin films

2Ease of manufacture

If the electrically conductive path is accommodated with clearance in the sheath member, then the insertion is facilitated, but dust or sand enters the sheath member and causes accelerated damage through abrasion

Engineering Contradiction:

Improveinsertion facilitationVSAvoidabrasion from dust or sand

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The sheet member serves as a barrier that prevents dust and sand from entering the clearance space between the electrically conductive path and the sheath member. By filling this space, the sheet member eliminates the pathway for contaminant ingress while still allowing for easy insertion during manufacturing

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The clearance space that initially causes harm by allowing dust and sand entry is converted into a beneficial feature by filling it with the sheet member. This transformation turns the problematic space into a protective barrier that prevents contaminant ingress and protects the electrically conductive path from abrasion

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Data Source

PatentUS9776580B2Wire harness

Publication Date: 2017.10.03 YAZAKI CORP

AI summary

A wire harness is provided with an electrically conductive path, a tubular sheath member which accommodates the electrically conductive path in an inner part, and a sheet member positioned between at least a part of a circumferential direction of the electrically conductive path and an inner peripheral surface of the sheath member. The sheet member may be wound on the electrically conductive path so as to cover an entire area in the circumferential direction. The sheet member may be intermittently arranged in an axial direction of a tube of the sheath member.