Method of forming a protective covering for a wire harness

• US 7,908,742 B2
• Filed: 03/25/2008
• Issued: 03/22/2011
• 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
• Primary Examiner(s): Banks; Derris H
• Assistant Examiner(s): NGUYEN, TAI V
• Application Number:
  US12/055,070
• Publication Number:
  US 20090241331A1
• Time in Patent Office: 1,092 Days
• Field of Search: 298/25, 298/32, 298/52, 298/46, 298/72, 297/25, 29/33.M, 296/146.6, 296/202, 296/35.2, 264/46.5, 264/46.7, 264/46.9, 439/34, 439/502, 249/91, 249/164
• 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,

wherein the wire harness is positioned in the post-molding fixture within a first predetermined time after introduction of the injection molding liquid.

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 there between 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 isocyanate 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 second predetermined time after the injection molding liquid is introduced into the cavity.

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

8. The method of claim 1 wherein the first predetermined time is less than 36 hours.

9. The method of claim 8 wherein the first predetermined time is less than one hour.

10. 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.

11. The method of claim 10 further comprising marking the base with a pattern corresponding to the desired geometry.

12. The method of claim 10 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.

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