System and Method of Forming a Protective Covering for a Wire Harness

• US 20090241331A1
• Filed: 03/25/2008
• Published: 10/01/2009
• Est. Priority Date: 03/25/2008
• Status: Active Grant

• Current Assignee: Commercial Vehicle Group Incorporated
• Original Assignee: Commercial Vehicle Group Incorporated
• Inventors: Buck, Frederick Allan, Bedoe, Scott
• Granted Patent: US 7,908,742 B2
• Time in Patent Office: Days
• US Class Current: 29/825
• CPC Class Codes: B60R 16/0215 Protecting, fastening and routing means therefor
• CPC Class Codes: H01B 13/01254 Flat-harness manufacturing
• CPC Class Codes: H02G 3/0475 formed by a succession of articulated units
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49121 Beam lead frame or beam lead device
• CPC Class Codes: Y10T 29/4913 Assembling to base an electrical component, e.g., capacitor, etc.
• CPC Class Codes: Y10T 29/49165 by forming conductive walled aperture in base
• CPC Class Codes: Y10T 29/49201 with overlapping orienting
• CPC Class Codes: Y10T 29/5193 Electrical connector or terminal
• CPC Class Codes: Y10T 29/53204 Electrode
• CPC Class Codes: Y10T 29/53209 Terminal or connector
• CPC Class Codes: Y10T 29/53213 Assembled to wire-type conductor

Abstract

A system and method for forming a wire harness covering having a predetermined three-dimensional geometry is provided. The system and method make use of a mold and a post-molding fixture. In a first phase, the mold is used during an injection molding process to form a substantially flat and partially-cured harness covering having an intermediate, substantially two-dimensional shape. In a second phase, the post-molding fixture is used after the injection molding process to orient the harness with covering to a predetermined three-dimensional geometry corresponding to the desired final shape.

Claims

1. A method for forming a wire harness covering having a predetermined three-dimensional geometry comprising:

providing an injection mold that defines a mold cavity;

positioning a wire harness within the cavity of the mold;

introducing an injection molding liquid into the cavity of the mold to form a covering about the wire harness;

removing the wire harness from the mold before the covering is fully cured;

providing a post-molding fixture corresponding to the desired predetermined three-dimensional geometry for the wire harness covering; and

positioning the wire harness with the partially-cured covering in the post-molding fixture in accordance with the desired predetermined three-dimensional geometry.

2. The method of claim 1 wherein the injection mold comprises a top half and a bottom half for engagement with one another and defining the cavity therebetween when the halves are engaged.

3. The method of claim 2 further comprising:

disengaging the top half and bottom half of the mold;

positioning the wire harness in the portion of the cavity defined by the bottom half of the mold; and

engaging the top half and bottom half to hold the wire harness in the cavity.

4. The method of claim 1 wherein the injection molding liquid forms a thermosetting polymer covering.

5. The method of claim 4 wherein the injection molding liquid comprises a mixture of a polyol and an isocyante that are combined in a reaction injection molding process to form a polyurethane polymer.

6. The method of claim 1 wherein the wire harness is removed from the injection mold at a first predetermined time after the injection molding liquid is introduced into the cavity.

7. The method of claim 6 wherein the first predetermined time is less than one hour.

8. The method of claim 1 wherein the wire harness is positioned in the post-molding fixture within a second predetermined time after introduction of the injection molding liquid.

9. The method of claim 8 wherein the second predetermined time is less than 36 hours.

10. The method of claim 9 wherein the second predetermined time is less than one hour.

11. The method of claim 1 wherein the post-molding fixture comprises a base with guide members projecting from the base for orienting the wire harness in accordance with the predetermined three-dimensional geometry.

12. The method of claim 11 further comprising marking the base with a pattern corresponding to the desired geometry.

13. The method of claim 11 wherein the step of positioning the partially-cured wire harness in the post-molding fixture comprises bending the harness about the guide members and manipulating the harness into the predetermined three-dimensional geometry.

14. The method of claim 1 further comprising fastening the wire harness with the partially-cured covering to the post-molding fixture.

15. A system for forming a wire harness covering according to a predetermined three-dimensional geometry comprising:

a wire harness;

an injection mold including two mold halves defining a cavity therebetween and that is substantially flat in shape for forming a partially-cured wire harness covering having an intermediate, substantially two-dimensional shape; and

a post-molding fixture for orienting the partially-cured wire harness covering in accordance with the predetermined three-dimensional geometry.

16. The system of claim 15 wherein the cavity comprises sub-cavities for forming a corrugated covering of a predetermined thickness for the wire harness.

17. The system of claim 15 wherein the post-molding fixture comprises a base with guide members projecting from the base for orienting the wire harness in accordance with the predetermined three-dimensional geometry.

18. The system of claim 17 wherein the guide members are pins.

19. The system of claim 18 wherein the pins are disposed in pin receiving holes in the base.

20. The system of claim 19 wherein the pin receiving holes are arranged about the base according to a predetermined configuration.

21. The system of claim 17 wherein the guide members are walls.

22. The system of claim 21 wherein the base has a top surface and the walls are upstanding from the top surface.

23. The system of claim 21 wherein at least one of the walls has a tab protruding from the at least one wall.

24. The system of claim 15 wherein the post-molding fixture is made from one of wood, fiberglass, composite, metal, paper, or cardboard.

25. The system of claim 15 wherein the post-molding fixture comprises a tie for engaging two portions of the harness for holding the harness in a fixed position while the covering is curing.