Wiring Module Bending Mitigation for Wire Protection
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Solution Overview
Problem
Existing wiring modules face challenges in minimizing damage to single-core wires when connecting them to stranded wires, as the connection portion is often wider than the pipe, leading to deformation risks and difficulty in inserting components without damaging the braided members or second conductors.
Innovation Solution
A wiring module with a bending mitigating member featuring a spiral wire-like body that surrounds the single-core wire, allowing for elastic deformation and easy insertion, while a locking protrusion and recessed portion secure the member to the external covering pipe, preventing direct contact with the pipe's edge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the connection portion between the first conductor and second conductor is arranged outside of the pipe, then the connection can be performed after insertion, but the single-core wire is forcefully pressed against the inner circumferential edge portion of the opening portion causing deformation
Solution Approach 1:
A buffer member (stress mitigating member) is introduced as an intermediary component between the single-core wire and the pipe opening edge. This buffer member absorbs the pressing force and prevents direct contact between the wire and the sharp edge, thereby eliminating the deformation problem while maintaining the connection arrangement outside the pipe
Solution Approach 2:
The buffer member is installed beforehand at the pipe opening to provide cushioning protection. By preparing the protective element in advance, the system prevents harmful effects before they occur, allowing the connection portion to be arranged outside the pipe without risking wire deformation
2Object-affected harmful factors
If a rubber stress mitigating member with insertion hole is used, then bending stress is mitigated, but it is difficult to perform the operation of inserting the first conductor, connection member, and second conductor into the insertion hole
Solution Approach 1:
The stress mitigating member transitions from a rigid rubber structure to a flexible spiral wire-like structure that can dynamically adjust its shape. This spiral configuration allows the member to compress and expand, enabling easy insertion through the pipe opening while maintaining stress mitigation functionality
3Object-affected harmful factors
If a spring stress mitigating means is used, then bending stress is mitigated, but the end portion of the wire-like member is exposed at the outer end portion and may damage the braided member or second conductor
Solution Approach 1:
The spiral wire-like buffer member is designed to surround and contain the single-core wire within its spiral structure. This nested configuration ensures that the protective element envelops the wire completely, preventing exposure of sharp edges that could damage the braided member or second conductor
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 solution effectively suppresses deformation of single-core wires, minimizes damage, and facilitates easy attachment by supporting the wires to prevent bending and ensuring secure fixation within the pipe.
Implementation Method 1
a bending mitigating member capable of undergoing elastic bending deformation more easily than the external covering pipe
Data Source
AI summary
A wiring module equipped with an external covering member includes an external covering pipe; a first conductive wire member that is inserted into the external covering pipe, a first end portion of the first conductive wire member extending from a first-end opening portion of the external covering pipe; a second conductive wire member that is connected to the first end portion of the first conductive wire member via a connection portion that is located outward of the first-end opening portion of the external covering pipe; and a bending mitigating member that is capable of undergoing elastic bending deformation more easily than the external covering pipe, a first end portion of the bending mitigating member being fixed to the first-end opening portion of the external covering pipe, and the bending mitigating member extending up to the connection portion or beyond the connection portion while surrounding the first conductive wire member.