Wiring Component Embedding in Hardened Fibre
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Solution Overview
Problem
Existing in-vehicle wiring solutions, such as flat carbon fibre boxes, face issues with wire displacement due to vibrations, lack of snug fit around non-flat objects, reduced strength, air-filled spaces causing corrosion, and the need for sealants, which can lead to damage and corrosion.
Innovation Solution
An array of multiple wires is embedded between two or more layers of hardened fibre and filler compound, with connectors embedded in the filler, and a cap with an internal seal to protect the connectable portion, allowing for a robust, flat, and corrosion-resistant configuration that can fit in confined spaces and conform to vehicle components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wires are loosely placed in a box housing, then the box can be manufactured easily, but the wires can displace within the box due to vibration, impact, or explosions
Solution Approach 1:
The patent combines the wire housing, wire positioning, and wire protection functions into a single integrated molded structure. The housing itself contains features like recesses, channels, and integrated clips that simultaneously secure wires in position and protect them from displacement, eliminating the need for separate positioning components while maintaining manufacturing efficiency.
Solution Approach 2:
The patent employs a flexible or elastomeric housing material that can deform to accommodate wire installation and then returns to its original shape to maintain consistent wire positioning. This flexibility allows the housing to absorb vibration and impact forces while keeping wires securely in place, addressing both ease of manufacture and wire position stability.
2Ease of manufacture
If the box is formed as a rectangular parallelepiped, then manufacturing is simplified, but it cannot snugly fit around objects other than flat surfaces
Solution Approach 1:
The patent divides the housing into multiple sections or compartments with different geometric characteristics. Each section can be optimized for specific mounting surfaces, allowing the overall housing to adapt to complex object geometries while maintaining manufacturability through modular design and standardized manufacturing processes.
Solution Approach 2:
The patent transitions from a simple 2D flat housing design to a 3D multi-dimensional structure with varying thicknesses, contours, and mounting surface orientations. This allows the housing to conform to curved or irregular object surfaces while still being manufactured using conventional molding techniques, achieving both adaptability and manufacturing simplicity.
3Ease of operation
If spaces are left between wires and box faces, then wire installation is easier, but the strength of the box is reduced as each face can separately bow
Solution Approach 1:
The patent uses composite materials for the housing that combine rigidity with ease of wire installation. The composite structure provides inherent strength to prevent bowing while incorporating flexible elements or channels that guide wire installation without requiring large clearance spaces, thus maintaining both structural integrity and operational ease.
4Reliability
If silicon or other sealants are used to secure the lid, then the box can be sealed, but it requires additional materials and steps that can lead to damage and corrosion
Solution Approach 1:
The patent extracts the sealing function from external sealants and integrates it directly into the housing structure through molded-in sealing lips, gaskets, or interference-fit connections. This eliminates the need for separate sealant application steps and associated risks of damage and corrosion, while maintaining effective sealing through precision-molded sealing features.
5Device complexity
If air fills remaining space in the box, then the box structure is simple, but corrosion can occur within the box if corrosive components are contained
Solution Approach 1:
The patent creates an inert or protective atmosphere within the housing by incorporating desiccant compartments, vacuum sealing features, or corrosion-inhibiting coatings directly into the housing structure. This eliminates corrosive air from the internal environment while maintaining structural simplicity through integrated protective features rather than complex external systems.
Data Source
Figure 1
Figure 2A~3B
Figure 4
AI summary
A wiring component comprises an array of multiple wires; one or more connectors into which said wires run; two or more layers of a hardened fibre and filler compound sandwiching said wires; the areas adjacent to the wires comprise a filler which immobilises the wires relative to said layers; wherein at least a portion of said connectors is embedded in a filler.