Wire Harness Splice Waterproofing With Resin Inter-Wire Filling
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Solution Overview
Problem
Existing wire harnesses with splice portions face challenges in achieving high waterproofing performance, especially in environments where water contact is likely and temperature changes occur, due to limitations in the structure and material of traditional waterproofing members.
Innovation Solution
A wire harness design that includes a wire bundle with exposed conductors bonded at a splice body, covered by insulating coverings, and a resin-based waterproofing cover that integrally covers the splice body and adjacent regions, featuring an inter-wire filling portion that fills the space between wires, enhancing adhesion and stress mitigation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a waterproofing member is provided to cover the splice portion, then waterproofing performance is improved, but the structure becomes more complex and manufacturing difficulty increases
Solution Approach 1:
The patent combines the waterproofing member with the insulating covering to form an integrated structure. The waterproofing member is formed to continuously cover the splice portion and seamlessly connect with the insulating covering of the wire, eliminating the need for separate waterproofing components and reducing structural complexity while maintaining high waterproofing performance.
Solution Approach 2:
The waterproofing member is constructed using a composite material system comprising a base resin layer and a waterproofing resin layer. This multi-layer composite structure provides enhanced waterproofing performance through the synergistic effects of different materials, while the integrated formation process keeps manufacturing straightforward.
2Reliability
If the waterproofing member structure is optimized for high waterproofing performance, then reliability improves, but ease of manufacture deteriorates
Solution Approach 1:
The patent applies preliminary action by forming the waterproofing member in an integrated process during the wire insulation formation stage. The waterproofing resin is applied and cured together with the insulating covering material in a single manufacturing sequence, ensuring high waterproofing performance is built-in from the outset without requiring subsequent separate waterproofing operations.
Solution Approach 2:
The manufacturing process merges the formation of the insulating covering and the waterproofing member into a single integrated operation. Both layers are formed simultaneously in one manufacturing step, which simplifies the overall production process while ensuring the waterproofing member achieves optimal performance through proper integration with the insulating covering.
3Reliability
If the waterproofing cover integrally covers the splice body and covered region, then waterproofing performance improves, but the volume of material required increases
Solution Approach 1:
The waterproofing cover is designed with local quality by concentrating the waterproofing resin material specifically at critical areas where water penetration risk is highest. The cover provides enhanced waterproofing at the splice portion and gradually transitions to match the insulating covering in the covered region, ensuring high reliability while minimizing unnecessary material usage in areas where full waterproofing coverage is less critical.
Solution Approach 2:
The patent employs parameter changes by varying the thickness and material composition of the waterproofing cover across different regions. The waterproofing resin layer is thickest at the splice portion where maximum waterproofing is needed and tapers off toward the covered region, optimizing the balance between waterproofing performance and material volume.
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 design provides a high waterproofing property to the splice portion, maintaining effectiveness even in environments with water exposure and temperature fluctuations, by increasing the contact area and mitigating stress between the resin and insulating coverings.
Implementation Method 1
the waterproofing cover includes an inter-wire filling that covers an entire circumference of at least one of the wires forming the wire bundle, and is obtained by filling a region between the wires with the resin material
Implementation Method 2
enhancing adhesion and stress mitigation
Data Source
AI summary
A wire harness including: a wire bundle that includes a plurality of wires, each wire of the plurality of wires includes a conductor and an insulating covering that covers an outer circumference of the conductor, and each wire of the plurality of wires includes an exposed portion at which the conductor is exposed from the insulating covering; a splice body; and a waterproofing cover, wherein: at the splice body, the exposed portions of the wires forming the wire bundle are bonded to each other, a portion of the wire bundle that is adjacent to the splice body and at which the conductors are covered by the insulating coverings is a covered region, the waterproofing cover integrally covers the splice body and the covered region with a resin material.