Wire Harness Exterior Body Structure for Stress-Resistant Mounting
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Solution Overview
Problem
Conventional wire exterior bodies suffer from mechanical weakness in branch and bent portions, leading to potential damage and reduced workability when attached to vehicles, and require high processing costs and extra materials.
Innovation Solution
A wire exterior body design featuring two wall parts facing each other across branch and bent portions, with one wall part fixed to improve mechanical strength and durability, and incorporating grooves to mitigate stress and prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If an exterior body is formed of a bent resin sheet to reduce weight, then weight is reduced, but mechanical strength in branch and bent portions deteriorates
Solution Approach 1:
The exterior body is divided into multiple wall parts (first wall part, second wall part, third wall part, fourth wall part) that are arranged to face each other across branch and bent portions. This segmentation provides mutual support and distributes mechanical loads, preventing concentration of stress at critical locations while maintaining the lightweight resin sheet construction.
Solution Approach 2:
The patent applies different structural configurations to different regions of the exterior body. Specifically, wall parts are positioned to face each other at branch and bent portions where mechanical strength is most needed, while other regions may have simpler structures. This local reinforcement strategy maintains overall lightweight design while addressing specific weakness points.
2Ease of operation
If a bellows structure is used to create bendable portions, then flexibility is improved, but processing costs increase and extra materials are required
Solution Approach 1:
The exterior body incorporates bendable portions that allow dynamic flexibility without requiring complex bellows structures. The bendable portions are integrated directly into the resin sheet through strategic positioning of wall parts and controlled bending zones, enabling the structure to adapt to routing requirements while simplifying manufacturing.
Solution Approach 2:
The patent merges the functions of flexibility and structural integrity by integrating bendable portions directly into the wall part structure. Instead of adding separate bellows components, the flexibility is achieved through the arrangement and configuration of the existing wall parts, combining multiple functions into a single integrated structure.
3Reliability
If locking parts are attached to the exterior body for securing to vehicle body, then attachment function is improved, but stress concentration damages the exterior body
Solution Approach 1:
The patent positions wall parts to face each other in advance of where locking parts will be attached, creating a reinforced zone that cushions and distributes the stress before it concentrates at the locking part attachment points. This preemptive structural arrangement prevents stress-induced damage while maintaining secure attachment capability.
4Adaptability or versatility
If the exterior body is provided with branch portions and bent portions for route regulation, then route flexibility is improved, but mechanical strength deteriorates
Solution Approach 1:
The exterior body is segmented into multiple wall parts that can be independently positioned and configured to create branch and bent portions. This segmentation allows the structure to accommodate complex routing requirements while each wall part maintains its structural integrity and provides mutual support at junction points.
Solution Approach 2:
The patent applies enhanced structural configuration specifically at branch and bent portions where wall parts face each other, providing localized reinforcement exactly where route regulation creates mechanical weakness. Other portions of the exterior body maintain simpler structures, optimizing the balance between route flexibility and overall strength.
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A wire exterior body and an exterior-covered wire harness in which damage by an attaching member is prevented are provided. A wire exterior body (3) to be mounted on the outer periphery of an electric wire (wire harness) (2), the wire exterior body being formed of a resin sheet that is bent, includes a plurality of wall parts (4) extending along an extending direction of the electric wire and forming an accommodating part (5) that accommodates the electric wire. Among the plurality of the wall parts (4), at least one wall part (upper lid wall part (45)) has a through-hole (47), penetrating in a thickness direction of the resin sheet, into which an attaching member (61) attachable to a vehicle body is inserted, and a groove (a lower surface groove (48) or an upper surface groove (49)) in which a thickness of the resin sheet is reduced is formed on a part around the through-hole (47) on at least one surface of an upper surface (45c) and a lower surface (45d) facing the thickness direction.