Wire Harness Shield Conductive Path Asymmetry
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Solution Overview
Problem
Conventional wire harnesses with circular cross-sectional electrical lines form large gaps when inserted into pipes, making it difficult to reduce the pipe diameter and increase space efficiency.
Innovation Solution
The wire harness features single-core electrical lines with insulating sheathing and facing surfaces arranged to maintain an approximately uniform gap when inserted, along with flat fixing surfaces for easy connection and reduced pipe diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If circular cross-sectional electrical lines are bundled together, then the wire harness can be easily manufactured and assembled, but large gaps form between the electrical lines increasing the required pipe diameter
Solution Approach 1:
The patent applies asymmetry by changing the cross-sectional shape of electrical lines from circular to flat/rectangular. This asymmetric shape allows the lines to pack more efficiently when bundled, reducing gaps between adjacent lines. The flat configuration enables tighter packing density compared to circular shapes, thereby reducing the overall pipe diameter required while maintaining ease of assembly through standardized connectors.
2Area of stationary object
If electrical lines are bundled tightly to reduce gaps, then the pipe diameter can be reduced, but the lines may become difficult to connect and maintain
Solution Approach 1:
The patent applies segmentation by dividing the wire harness into modular sections with standardized connectors at intervals. Each segment can be independently connected and disconnected, allowing maintenance personnel to access specific lines without disturbing the entire bundle. This modular approach maintains tight packing for reduced pipe diameter while ensuring ease of connection through standardized interfaces.
Solution Approach 2:
The patent applies universality by implementing standardized connectors that can accommodate multiple electrical line configurations. The same connector type serves multiple functions: securing lines during installation, allowing for future modifications, and facilitating maintenance. This universal connector design ensures ease of operation while maintaining the compact bundled structure.
Data Source
AI summary
A wire harness includes a plurality of electrical lines to be collectively inserted into a pipe. Each of the electrical lines is a single-core line including a single-core conductor that is a single metal rod, and an insulating sheathing that envelops an outer circumference of the single-core conductor. Facing surfaces shaped so as to face each other across an approximately uniform gap in a facing direction when inserted into the pipe are formed on the plurality of electrical lines.