Wire Harness Ultrasonic Welding for Direct Attachment

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Solution Overview

Problem

Existing methods for attaching electric wires to exterior components in wire harnesses require additional components like tape or adhesive, which are unnecessary and can cause damage or inefficiency.

Innovation Solution

A wire harness with a functional exterior component shaped into a sheet, where the insulating covering of the electric wire is welded to the exterior component, allowing direct attachment without additional materials, and utilizing ultrasonic welding for secure bonding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If tape or adhesive is used to attach electric wires to exterior components, then the attachment can be achieved, but additional components are required and damage may occur

Engineering Contradiction:

Improveattachment processVSAvoidnumber of components

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The insulating covering and exterior component are merged into a single integrated structure where the insulating covering is welded directly to the exterior component, eliminating the need for separate attachment materials like tape or adhesive

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mechanical attachment method using tape or adhesive is replaced with ultrasonic welding, which uses ultrasonic vibration to create a direct bond between the insulating covering and exterior component

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If tape or adhesive is used for attachment, then the electric wires can be attached, but the process becomes more complex and time-consuming

Engineering Contradiction:

Improveattachment securityVSAvoidattachment efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The mechanical attachment process using tape or adhesive is replaced with ultrasonic welding, which uses ultrasonic vibration to create a direct bond, significantly reducing attachment time and improving productivity while maintaining secure attachment

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The attachment method changes from chemical/adhesive-based to ultrasonic vibration-based, fundamentally altering the process parameters to achieve faster and more efficient attachment

Inventive Principle:

Principle #35Parameter changes

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

This method enables direct and secure attachment of electric wires to exterior components, eliminating the need for tape or adhesive, while enhancing soundproofing, shielding, heat radiation, and tensile strength, and simplifying the attachment process.

Implementation Method 1

at least a part of an overlap between an insulating covering of the electric wire and the functional exterior component is ultrasonic-welded

Methodology Applied

Scientific EffectUltrasonic welding: Ultrasonic Vibration

Data Source

PatentUS10867721B2Wire harness

Publication Date: 2020.12.15 AUTONETWORKS TECH LTD

AI summary

A wire harness includes a functional exterior component shaped into a sheet and an electric wire disposed to overlap with the functional exterior component in at least a part of a region along a longitudinal direction. At least a part of an overlap between the insulating covering of the electric wire and the functional exterior component is welded.