Wiring Member with Segmented Sheath Gap for Flexibility
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Solution Overview
Problem
Existing molded portion-equipped wiring members have poor flexibility due to insulating coverings that are in close contact with conductors, limiting their usability in applications requiring bending or movement.
Innovation Solution
A wiring member design featuring a conductor portion, terminal, molded portion, and sheath member with a gap between the sheath and conductor, and adhesives or elastic ring-shaped portions to enhance flexibility and water resistance, allowing the conductor to bend easily while preventing liquid intrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulating covering is in close contact with the conductor, then the insulation performance is improved, but the flexibility of the wiring portion deteriorates
Solution Approach 1:
The sheath member is divided into multiple sections: a first section that is in close contact with the molded portion, a second section that forms a gap with the conductor, and a third section that is in close contact with the conductor. This segmentation allows different portions of the sheath to serve different functions - insulation where needed and flexibility where required.
Solution Approach 2:
The sheath member has different structural characteristics at different locations. The first section provides tight insulation against the molded portion, while the second section creates a gap for flexibility, and the third section provides local contact with the conductor. This local differentiation resolves the contradiction between overall insulation performance and local flexibility.
2Reliability
If the sheath member is in close contact with the conductor throughout, then the water-stopping capability is improved, but the flexibility and ease of bending deteriorates
Solution Approach 1:
The sheath member is segmented into three distinct sections along its length, with the second section forming a gap with the conductor. This segmentation allows the water-stopping function to be maintained at the interfaces (first section with molded portion, third section with conductor) while the middle section provides flexibility through the gap.
Solution Approach 2:
The second section of the sheath member acts as an intermediary element between the first and third sections. By forming a gap with the conductor in this intermediate section, it allows bending flexibility while the adhesive sections at both ends maintain water-stopping capability.
3Reliability
If adhesives are applied to seal the interface between sheath member and molded portion, then the water-stopping capability is improved, but the manufacturing complexity increases
Solution Approach 1:
The sheath member is designed with predetermined sections for adhesive application, specifically the first section that contacts the molded portion. This preliminary design of the adhesive application location and method simplifies the manufacturing process by eliminating the need for complex sealing mechanisms.
Solution Approach 2:
The adhesive acts as an intermediary substance between the sheath member and the molded portion, creating a simple yet effective seal at the interface. This approach is easier to manufacture than mechanical sealing methods while providing reliable water-stopping capability.
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 design achieves excellent flexibility and improved water-stopping capabilities by allowing the conductor to bend and using adhesives or elastic deformation to seal potential entry points for liquids, reducing the risk of water intrusion and part count.
Implementation Method 1
a first adhesive that is provided between the outer circumferential surface of the end portion of the sheath member and the inner circumferential surface of the second end portion of the molded portion, and that causes the outer circumferential surface of the end portion of the sheath member and the inner circumferential surface of the second end portion of the molded portion to be in close contact with each other
Implementation Method 2
the sheath member includes an elastic ring-shaped portion that is a portion formed at the end portion, is capable of undergoing elastic deformation, and has an inner circumferential surface that comes into close contact with an outer circumferential surface of the second end portion of the molded portion
Data Source
AI summary
A molded portion-equipped wiring member includes a conductor portion that is wire-shaped, a terminal that is connected to an end portion of the conductor portion, a molded portion that covers a connection portion between the conductor portion and the terminal such that the terminal projects from a first end portion side and the conductor portion extends from a second end portion side, and a sheath member that surrounds the conductor portion in a state where a gap of separation from the conductor portion is formed in an intermediate portion, the sheath member being in close contact with the second end portion of the molded portion in an end portion.