Wire Harness Exterior Member Welding for Strong Vehicle Fixing
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Solution Overview
Problem
Existing wire harnesses face challenges in appropriately fixing exterior members, such as protectors, to vehicles due to inadequate bonding strength between the protector body portion and the vehicle fixing portion.
Innovation Solution
The wire harness includes a protective member with unevenness on its surface and a fixing member welded to this unevenness, allowing the protective member to be securely fixed to a vehicle by concentrating thermal energy during welding, thereby enhancing bonding strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a protector body portion is welded to a vehicle fixing portion without surface unevenness, then the welding process is simple, but the bonding strength between the protector body portion and the vehicle fixing portion is insufficient
Solution Approach 1:
The protective member incorporates localized surface unevenness (protrusions and recesses) at specific welding areas rather than changing the entire structure. This local modification concentrates thermal energy during welding to enhance bonding strength precisely where needed, without complicating the overall device design.
Solution Approach 2:
The surface unevenness is pre-formed on the protective member before the welding process. This preliminary structural preparation ensures that when welding occurs, the thermal energy is automatically concentrated at the protrusion tips, guaranteeing strong bonding without requiring complex welding process control.
2Strength
If thermal energy is concentrated during welding to enhance bonding strength, then the bonding strength increases, but the welding process becomes more complex
Solution Approach 1:
The protective member's surface unevenness structure enables self-concentration of thermal energy during welding. The protrusions naturally focus the heat from the welding tool onto specific areas, achieving enhanced bonding strength without requiring complex welding process control or additional equipment.
Solution Approach 2:
The invention changes the physical parameter of the protective member's surface geometry (creating protrusions and recesses) to alter how thermal energy distributes during welding. This structural parameter change automatically focuses heat concentration, simplifying the welding process while maintaining strong bonding.
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 configuration ensures that the wire harness and exterior member can be appropriately fixed to a vehicle, reducing costs and assembly time while maintaining strong bonding strength regardless of the material used for the protective member.
Implementation Method 1
concentrating thermal energy during welding, thereby enhancing bonding strength
Data Source
AI summary
A wire harness includes: a wiring member having conductivity; and an exterior member that is attached to the wiring member. The exterior member includes a protective member in which unevenness is formed on a surface and that is formed in a tubular shape to be able to protect the wiring member inserted therein, and a fixing member that is welded to the unevenness of the protective member and is capable of fixing the protective member to a fixing target portion.