Wiring Member Resin Bracket Flat Surface Crimping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing wiring techniques face challenges in securely attaching brackets to bracket attachment portions, particularly with round shapes, leading to difficulties in regulating the angle of brackets and cables due to potential rotation.
Innovation Solution
A wiring member design featuring a resin molded portion with a quadrate-shaped bracket attachment portion and a bracket with a second attachment portion that makes surface contact with multiple flat surfaces, preventing rotation and allowing for precise angle regulation during crimping, while also applying crimping force to a sheath rather than the wires to prevent deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the bracket attachment portion has a round shape, then it is easy to manufacture, but the bracket may rotate around the periphery and it becomes difficult to regulate the angle of the bracket and cable
Solution Approach 1:
The bracket attachment portion is designed with an asymmetric flat surface portion instead of a completely round shape. This asymmetric feature prevents rotation while maintaining ease of manufacture, as the flat surface can be easily formed during the molding process of the resin molded portion.
Solution Approach 2:
Only a specific local region of the bracket attachment portion is made flat, while the rest maintains the round shape. This local flat surface portion provides the necessary angle regulation capability without significantly complicating the overall manufacturing process.
2Reliability
If the bracket is crimped to a round bracket attachment portion, then the bracket can be attached, but the bracket may rotate and the angle cannot be regulated
Solution Approach 1:
The flat surface portion creates an asymmetric contact interface between the bracket and the attachment portion. This asymmetry ensures that the bracket cannot rotate freely, allowing the operator to regulate and fix the angle precisely while maintaining secure attachment.
Solution Approach 2:
The flat surface portion acts as an intermediary feature that mediates between the bracket and the round attachment portion. It provides a stable contact surface that prevents rotation while still allowing the bracket to be crimped securely to the attachment portion.
3Reliability
If crimping force is applied directly to the wires, then the bracket can be attached, but the wires may deform
Solution Approach 1:
The sheath serves as an intermediary structure between the bracket and the wires. The crimping force is applied to the sheath first, which then distributes the force uniformly to the wires, preventing direct concentrated stress that would cause wire deformation while maintaining secure attachment.
Solution Approach 2:
The sheath acts as a flexible protective shell that surrounds the wires. By crimping the bracket to the sheath rather than directly to the wires, the flexible sheath absorbs and distributes the mechanical stress, protecting the wires from deformation while maintaining the attachment's reliability.
Data Source
AI summary
A wiring member includes wires, a resin molded portion that covers the wires, and a bracket attachment that is attached to the resin molded portion. The resin molded portion includes a bracket attachment portion that is formed with at least one flat surface portion. The bracket includes a first attachment portion that is configured to be attached to an attachment location, and a second attachment portion that is connected to the first attachment portion and is crimped to the bracket attachment portion while being in surface contact with at least one of the at least one flat surface portion.