Instrument Panel Wire Harness Layout for Stable Flexible Substrate Assembly

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Solution Overview

Problem

Conventional wire harnesses with flexible substrates face challenges in stable assembly due to their deformability, making it difficult to mount them securely on vehicle bodies.

Innovation Solution

A wire harness design that incorporates a flexible substrate disposed along a reinforcement within the instrument panel, eliminating three-dimensional routing and allowing for easier assembly by attaching the flexible substrate to a structural member, thereby improving assemblability and reducing installation space.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a flexible substrate is used in a wire harness, then flexibility and adaptability are improved, but assembly stability deteriorates due to easy deformation

Engineering Contradiction:

ImproveflexibilityVSAvoidassembly stability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

A reinforcement member is introduced as an intermediary component between the flexible substrate and the vehicle body. The reinforcement member has higher rigidity than the flexible substrate and serves as a stable mounting base, allowing the flexible substrate to be securely attached while maintaining its inherent flexibility for routing adaptations.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The wire harness is divided into distinct functional segments: the flexible substrate for electrical connections and routing, and the separate reinforcement member for structural support and mounting. This segmentation allows each component to optimize its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If three-dimensional routing is used for the flexible substrate, then adaptability to vehicle layout is improved, but assembly difficulty and time increase

Engineering Contradiction:

Improverouting adaptabilityVSAvoidassembly efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The flexible substrate is pre-attached to the reinforcement member during manufacturing, creating a pre-assembled unit with predetermined routing paths. This preliminary action eliminates the need for complex three-dimensional routing adjustments during vehicle assembly, significantly improving assembly efficiency while maintaining routing adaptability.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If extensive flexible substrate is used for comprehensive wiring, then coverage and functionality are improved, but cost and instrument panel size increase

Engineering Contradiction:

Improvewiring coverageVSAvoidinstrument panel size

Core Design Contradiction:

Adaptability or versatilityVSArea of stationary object

Solution Approach 1:

The reinforcement member acts as a thin, rigid framework that provides structural support without occupying significant space. The flexible substrate is attached to this framework, allowing comprehensive wiring coverage to be achieved with minimal increase in instrument panel thickness or overall size.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS20250018884A1Wire harness

Publication Date: 2025.01.16 YAZAKI CORP

AI summary

A wire harness includes a trunk module having a flexible substrate having flexibility, and a branch wire module having an electric wire connected to the flexible substrate. The flexible substrate is disposed along a reinforcement provided in an instrument panel and extending in a vehicle width direction of a vehicle, and is assembled to the reinforcement.