Wire Harness Silencer With Deformable Cover
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Solution Overview
Problem
The increasing number of electrical wires in vehicles poses a challenge for conventional wire harness installation spaces, particularly in areas like the side sill and cross member, leading to a high risk of wire harnesses being stepped on by occupants, necessitating new measures for protection.
Innovation Solution
A wire harness arrangement structure featuring a silencer with a recessed groove and a deformable cover that can extend outward when a force is applied, providing protection by bowing the silencer and reducing the likelihood of the wire harness being stepped on, with optional features including a carpet covering and integral design for reduced component count and increased stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the wire harness is arranged in the silencer, then the degree of freedom in arranging the wire harness is increased, but the risk of the wire harness being stepped on by occupants increases
Solution Approach 1:
The silencer is divided into multiple regions: a first region without the groove where occupants can step normally, and a second region with the groove and cover structure that protects the wire harness. This segmentation allows the wire harness to be arranged in the silencer while protecting it from stepping by creating a dedicated protected zone separated from the stepping area.
Solution Approach 2:
A cover member is introduced as an intermediary structure between the wire harness and the external environment. The cover includes a groove that houses the wire harness and a deformable lid that can extend outward when stepped on, providing protection while allowing force dissipation. This intermediary structure enables the wire harness to benefit from the silencer's space while being protected from direct stepping contact.
2Reliability
If a cover structure is added to protect the wire harness in the silencer, then the protection against stepping is improved, but the number of components and device complexity increases
Solution Approach 1:
The cover member serves multiple functions: it protects the wire harness from stepping, provides a deformable structure that dissipates stepping forces, and integrates with the silencer's existing structure. The lid portion can act as a protective shield while also allowing controlled deformation to release stress. This multi-functionality reduces the need for additional separate protection components.
Solution Approach 2:
The lid of the cover member is designed with flexible properties, allowing it to deform and extend outward when stepped on. This flexibility enables the structure to absorb and dissipate stepping forces without requiring heavy reinforcement or complex mechanical protection systems. The deformable lid provides effective protection while maintaining a simple and lightweight structure.
3Strength
If the lid is made rigid to protect the wire harness, then the protection strength is improved, but the ability to dissipate stepping force is reduced
Solution Approach 1:
The lid is designed with dynamic characteristics, allowing it to deform and extend outward when stepped on. This dynamic response enables the structure to adapt to external forces by changing its configuration, thereby dissipating stepping forces through controlled deformation rather than rigid resistance. The lid can return to its original position after deformation, providing continuous protection.
Solution Approach 2:
The material properties and structural parameters of the lid are optimized to balance strength and deformability. The lid is made sufficiently strong to protect the wire harness but with controlled flexibility to allow deformation under stepping forces. By adjusting parameters such as material selection, thickness, and geometric configuration, the lid achieves an optimal balance between protection strength and force dissipation capability.
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 effectively reduces the risk of wire harnesses being stepped on, increases the flexibility of wire harness arrangement, minimizes the number of components needed, and maintains sound insulation properties while enhancing the getting on/off properties of the vehicle.
Implementation Method 1
the cover is formed to be deformable so that the lid recesses and an opening at a bottom side of the groove extends outward when a force in a normal line direction with respect to a main surface of the lid is applied on the lid
Implementation Method 2
the silencer can be deformed so that a part supporting the wire harness bows when the lid presses the wire harness in deformation of the cover
Data Source
AI summary
A wire harness arrangement structure includes a silencer, the wire harness, and a cover. The silencer includes a silencer body with a groove recessed in a thickness direction is formed in a main surface of the silencer body. The groove houses at least part of the wire harness. The cover includes a pair of legs covering both lateral sides of the wire harness housed in the groove and a lid covering an upper side of the wire harness housed in the groove and coupling the pair of legs together, and is open at a bottom side of the groove.