Electrical Wiring Structure with Crossing Lead Wires
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Solution Overview
Problem
The existing electrical wiring structure for connecting components with lead wires often faces difficulties in bending due to small bending radii and unbalanced restoring forces, especially with thick wires, leading to twisting issues when installed in internal-combustion engines.
Innovation Solution
The proposed electrical wiring structure uses lead wires inserted into arranged insertion portions in multiple lines and columns, with ends crossing at intermediate parts to equalize bending radii and restoring forces, allowing for easy bending and maintaining direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If lead wires are bent for connection, then the wiring can be adapted to component positions, but the bending radius becomes remarkably small making it difficult to bend
Solution Approach 1:
The patent introduces a intermediate part that positions the crossing point of lead wires at a specific location different from the component ends. This spatial reorganization in multiple dimensions allows the lead wires to achieve larger bending radii while still connecting the components, resolving the contradiction between wiring adaptability and bending ease.
2Adaptability or versatility
If lead wires are bent with different bending radii, then connection flexibility is achieved, but the restoring force becomes unbalanced causing the lead wires to twist
Solution Approach 1:
The patent designs the intermediate part and insertion portions such that all lead wires have equal lengths and equal bending radii. This creates equipotential conditions where the restoring forces of all lead wires are balanced, preventing twisting while maintaining connection flexibility. The symmetric arrangement ensures that no single wire experiences disproportionate stress.
3Power
If lead wires are made thick to handle large current, then current capacity is improved, but the bending difficulty increases due to larger restoring force
Solution Approach 1:
By reorganizing the spatial arrangement of lead wires through the intermediate part and crossing configuration, the patent enables thick wires (with higher current capacity) to be bent more easily. The optimized geometry distributes the bending stress more effectively, allowing thick wires to achieve the necessary connections without excessive bending difficulty.
Data Source
AI summary
An electrical wiring structure of connecting between a first component and a second component with at least four lead wires includes the first component provided with first insertion portions in which the lead wires are inserted, and the first insertion portions 15 are arranged in two lines and j columns, and the second component provided with second insertion portions in which the lead wires are inserted, and the second insertion portions are in two lines and j columns. Ends of a pair of lead wires are inserted into the first insertion portions and other ends of the pair of lead wires are inserted into the second insertion portions after crossing at an intermediate part.