Deformable Wiring Harness Clip for Shipping Protection and Release
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Solution Overview
Problem
Wiring harnesses in vehicle components, such as passenger airbag assemblies, are prone to damage during shipping due to inadequate securing methods like tape or rubber bands, leading to operational issues and excess wire length that interferes with other components during installation.
Innovation Solution
A deformable wiring harness clip with a body, wedged teeth, tension release lever, and hooks that securely holds the wiring harness in place during shipping and allows for easy installation by transitioning between mono-directional and bi-directional linear paths of the wire, using plastic deformation to accommodate different operational states.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the wiring harness is minimally secured to the passenger airbag assembly using tape or rubber bands, then the passenger airbag assembly can be easily manufactured and shipped, but the wiring harness is susceptible to damage, crimping, or breaking during the shipping process
Solution Approach 1:
The clip is divided into multiple functional segments: a body portion for structural support, a tensioning portion with teeth for gripping the wiring harness, and a lever portion for operation. This segmentation allows each part to perform its specific function efficiently while maintaining overall reliability during shipping.
Solution Approach 2:
The clip utilizes elastic deformation of the tensioning portion to dynamically adjust its grip on the wiring harness. When the lever is actuated, the tensioning portion deforms elastically to engage or disengage the teeth from the wiring harness, providing secure holding during shipping while allowing easy release when needed.
2Reliability
If the wiring harness is securely fastened during shipping, then damage prevention is improved, but excess wire length remains unsecured during installation, interfering with other vehicle components
Solution Approach 1:
The clip transitions from a secured state during shipping to an released state during installation through elastic deformation. The tensioning portion's ability to deform elastically allows the clip to hold the wiring harness securely during shipping, then easily release to allow proper wire length management during vehicle installation.
Solution Approach 2:
The lever-operated mechanism allows the installer to easily actuate the clip with simple manual force, and the elastic tensioning portion self-adjusts to release the wiring harness when the lever is moved, eliminating the need for additional tools or complex release mechanisms.
3Reliability
If a robust securing mechanism like a deformable clip with tension release lever is used, then the wiring harness is protected during shipping, but the device complexity increases compared to simple tape or rubber band solutions
Solution Approach 1:
By segmenting the clip into distinct functional portions (body, tensioning portion with teeth, and lever), the design achieves robust wiring harness security through specialized gripping mechanisms while keeping each segment relatively simple in structure, making the overall device manageable despite its enhanced functionality.
4Manufacturing precision
If the wire hole size is fixed, then the manufacturing precision is improved, but the clip cannot accommodate different wire sizes or installation states
Solution Approach 1:
The wire hole's effective size changes dynamically as the tensioning portion deforms elastically. When the lever is actuated, the tensioning portion compresses or expands, altering the wire hole dimensions to accommodate different wire sizes and configurations during installation, while maintaining precise manufacturing tolerances for the base structure.
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
The clip effectively prevents damage to the wiring harness during transit and ensures secure installation without excess wire, enhancing the reliability and efficiency of the wiring connection.
Implementation Method 1
using plastic deformation to accommodate different operational states
Data Source
AI summary
A deformable wiring harness clip includes a body, a plurality of wedged teeth, a wire hole, a tension release lever, and a pair of hooks. The body includes an interior portion, an exterior portion, a first side, and a second side. The plurality of wedged teeth are integrated with the interior portion of the body. Each of the plurality of wedged teeth has an angle defined from the first side of the body to the second side of the body. The wire hole is defined by the plurality of wedged teeth and is operable between a first size and a second size larger than the first size. The tension release lever is integrated with the body, protrudes away from the body, and is operable between a first state and a second state. The pair of hooks are integrated with the second side of the body.