Wire Harness Sheet Slit Design for Precise Manual Positioning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing wire harnesses using adhesive sheets are labor-intensive, require special equipment, and result in low yield rates due to difficulties in accurately positioning electric wire bundles and bending shapes, leading to increased costs and handling challenges.
Innovation Solution
A wire harness sheet with a rectangular shape and adhesive layer on one surface, featuring slits that allow for the placement and fixation of electric wire bundles using preliminary and main fixing sheet portions, enabling precise positioning without special machines and reducing material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If adhesive sheets are used to bundle electric wire bundles, then bonding efficiency is improved, but positioning precision deteriorates causing manufacturing difficulties
Solution Approach 1:
The adhesive sheet is segmented into multiple functional regions: a placement region with enhanced adhesive properties for precise wire bundle positioning, and a non-placement region without adhesive for handling and alignment. This segmentation allows the sheet to provide both strong bonding capability and precise positioning control simultaneously.
Solution Approach 2:
Different regions of the adhesive sheet are assigned different adhesive properties. The placement region has adhesive layers on both surfaces to ensure precise positioning and strong bonding, while the non-placement region has no adhesive to facilitate handling and alignment. This local differentiation resolves the contradiction between bonding efficiency and positioning precision.
2Adaptability or versatility
If sheet base material is cut to bending shapes, then adaptability to wire harness shapes is improved, but material waste increases
Solution Approach 1:
The adhesive sheet is prepared in advance with distinct placement and non-placement regions before being applied to the wire harness. The non-placement region extends beyond the placement region to provide handling margins and alignment guides, eliminating the need to cut the sheet to exact bending shapes and reducing material waste.
Solution Approach 2:
The adhesive sheet serves multiple functions: the placement region provides bonding and positioning, while the non-placement region provides handling convenience and alignment guidance. This multi-functionality allows a single sheet design to adapt to various wire harness configurations without requiring custom cutting for each shape.
3Strength
If adhesive is applied to bonding surfaces, then bonding strength is improved, but ease of operation deteriorates due to difficulty in peeling and repositioning
Solution Approach 1:
The adhesive sheet is divided into placement regions with strong adhesive properties for final bonding and non-placement regions without adhesive for easy handling and repositioning. This segmentation allows operators to easily adjust the sheet during positioning while ensuring strong bonding once the wire bundle is correctly placed.
Solution Approach 2:
Adhesive is applied locally only to the placement region where bonding is required, while the non-placement region remains adhesive-free for easy manipulation. This localized adhesive application provides both strong bonding strength where needed and ease of operation during the positioning process.
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 method allows for efficient, cost-effective, and easy handling of wire harness manufacturing by enabling manual precise positioning of electric wire bundles, improving yield rates, and simplifying the bonding process, thus reducing manufacturing time and costs.
Implementation Method 1
an adhesive layer is provided on one surface of the sheet base material on which an electric wire bundle is placed
Data Source
Figure 1
Figure 2(a)~2(d)
Figure 3
AI summary
Provided is a wire harness sheet by which it is possible to manually fix an electric wire bundle at an exact position without bending the electric wire bundle. A wire harness sheet 11 includes a sheet base material 13 that has a rectangular shape formed by a pair of first side portion 19 and a second side portion 21 in parallel with each other and by a third side portion 23 and a fourth side portion 25 orthogonal to the first side portion 19 and the second side portion 21; an adhesive layer 15 that is provided on one surface of the sheet base material 13; and a slit 17 which is cut into the sheet base material 13 in such a manner that the slit is formed along and in parallel with each the third side portion 23 and the fourth side portion 25 between each the first side portion 19 and the second side portion 21, and a placement region 31 of an electric wire bundle 27.