Abstract:
A routed part protector for protecting cables, wires, hoses, tubing and the like having a closed slot extending to a central aperture for inserting routed parts to be maintained in the aperture forming an assembly. The assembly can be attached to a vehicle trim panel by double-sided tape or other mechanical means or inserted into a ditch in a vehicle floorboard. The protector has a trapezoidal cross section body whereby the side walls can be deformed to open the slot to permit the routed parts to pass through when assembling the protector to a wire harness. The tape or the ditch then prevents the slot from opening.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. provisional patent application serial No. 60/118,395 filed Feb. 2, 1999. 
    
    
     BACKGROUND OF THE INVENTION 
     This invention relates to a wire harness protector that facilitates the mounting of wire harnesses into vehicle applications. 
     Wires harnesses are utilized in many vehicle applications to route a plurality of wires between various locations. Typically, wire harnesses have required complex assembly steps to position the wires at different locations and provide communication to and from various electrical components. This has sometimes resulted in undesirable buzz, squeak and rattle conditions. 
     Typically, wire harnesses have been snapped to vehicle trim panels after the assembly of the wire harness. This has proven somewhat complex, as the trim panel must be formed with wire harness holding structure. The wire harness is assembled at a distinct location shipped to the trim manufacturer, and then mounted to the trim panel. 
     It has sometimes been difficult to route wire harnesses, hoses, tubing, cables, or other routed parts at various locations within a vehicle, and yet still protect the parts. One example would be in the vehicle floorboard. The wire harness must typically extend beneath the carpet, and still be protected from damage caused by people walking on the carpet. 
     The present invention provides a simple apparatus that facilitates the mounting of wire harnesses to vehicle, and also protects the wire harnesses in many challenging environments. 
     SUMMARY OF THE INVENTION 
     The present invention concerns a wire harness protector for receiving a plurality of wires in a central aperture. A slot extends to the aperture from an outer surface of the protector body. The slot allows passage of a plurality of wires into the aperture when the slot is biased to an open position. However, the slot is normally biased to a closed position in a relaxed state that prevents movement of the wire harness out of the aperture. Thus, the wire harness protector may be utilized to receive a plurality of wires, and hold the wires. The wire harness protector protects the wire harness once the wire harness is received within the aperture. 
     The wire harness protector is preferably generally trapezoidal in cross section, with a smaller surface adjacent to the slot and a larger opposed surface. In One embodiment, the aperture has a major diameter and a minor diameter with the major diameter being greater than the minor diameter. Preferably, the major diameter extends perpendicular to the slot. This embodiment is particularly useful in reducing the height of a wire harness, as would be desirable when there is less available distance in one direction than there is in an opposed direction. In a sense, the aperture flattens the wire harness to better use available space. 
     In another feature of the present invention, the wire harness protector facilitates the attachment of the wire harness to trim panels. As an example, the wire harness protector may be provided with double-sided tape on one surface that secures the protector to the trim panel. The wire harness is secured to the protector, and thus is attached to the trim panel. 
     In one method according to this invention, the wire harness is assembled by moving the wires through the slot in the wire harness protector and into the aperture. Once the wire harness has been assembled into the wire harness protector, the assembly is then placed upon the trim panel. In this way, the separate steps of assembling the wire harness and then attaching the wire harness to the trim panel may be reduced. 
     In an alternative embodiment, the wire harness protector is secured to the trim panel, and a preassembled wire harness is then inserted through the slot and into the aperture. In a third possible embodiment, the wires could be individually assembled onto the trim panel after the protectors have been attached to the trim panel. 
     In another feature of this invention, a vehicle floorboard is provided with ditches to route wire harnesses, hoses, tubing, cables, or other routed parts between two locations. The ditches also preferably receive the wire harness connector with the wire harness retained in the central aperture. Preferably, the wire harness protector is positioned within the ditch such that the bottom wall of the ditch closes off the slot, thus preventing the wire harness from moving outwardly of the slot. The trapezoid shape allows positive routing with no variance in the direction that is perpendicular to the ditch. The soft covering suppresses buzz, squeak and rattle problems. Routing beneath the surface provides a safe environment, preventing damage to wiring from trim screws, seat mounts and other attaching hardware. 
     In other features of this invention, a secondary aperture and secondary slot are formed in the wire harness protector. This proves particularly valuable when an aftermarket wire is to be inserted into the vehicle. As an example, in the above-discussed embodiment wherein the wire harness is mounted into a vehicle floorboard, it may sometimes be necessary to mount additional wires such as when adding additional speakers, remote CD changer, or trailer tow by the original equipment manufacturer, dealership or vehicle owner. The secondary apertures are easily accessible to the assembler, and facilitate receipt and protection of the aftermarket wires for this additional wiring and function. 
    
    
     DESCRIPTION OF THE DRAWINGS 
     The above, as well as other advantages of the present invention, will become readily apparent to those skilled in the art from the following detailed description of a preferred embodiment when considered in the light of the accompanying drawings in which: 
     FIG. 1 is a perspective view showing the assembly of a wire harness into a wire harness protector in accordance with the present invention; 
     FIG. 2 shows a subsequent step in the assembly of the harness and protector of FIG. 1; 
     FIG. 3 shows the assembled wire harness and protector;. 
     FIG. 4 shows a subsequent step in the assembly; 
     FIG. 5 shows the attachment of the wire harness assembly to a trim panel; 
     FIG. 6 shows an alternative method of attachment; 
     FIG. 7 shows a first alternative protector; 
     FIG. 8 shows a second alternative protector; 
     FIG. 9 shows another attachment of the wire harness assembly to a vehicle; 
     FIG. 10 is a top plan view of vehicle floor; 
     FIG. 11 shows a third alternative protector; 
     FIG. 12 shows a fourth alternative protector; 
     FIG. 13 shows a fifth alternative protector; and 
     FIG. 14 shows a sixth alternative protector. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     FIG. 1 shows a routed part protector  20  having a central aperture  22  extending between end surfaces  21  and a slot  24  extending from a top surface  23  into the aperture  22 . The protector  20  can be formed of a foam or other compliant material, but is preferably formed of (EPDM) Ethylene Propylene Diene Monomer or similar rubber. Although the wire harness protector  20  is disclosed to protect wires in the preferred embodiment, use thereof to protect any routed part such as cables, hoses, tubing is within the scope and breath of the present invention. The wire harness protector  20  has a body of preferably generally trapezoidal cross-sectional shape with side walls  25  extending outwardly from the top surface  23  to an opposed bottom surface  27 . Since a width of the top surface  23  is smaller than a width of the bottom surface  27 , this facilitates the bending of the rubber protector  20  to expand the slot  24  to allow entry of a plurality of wires  26 . As shown in FIG. 2, when portions  28  of the top surface  23  of the protector  20  are pivoted apart such that a width of the slot  24  expands, the wires  26  may be inserted into the aperture  22 . In a relaxed state, the portions spring back together and the slot  24  is closed such as shown in FIG.  1 . 
     By utilizing this invention, the wire harness can be assembled into the protector  20  initially. The wires  26  are inserted into the slot  24  and, when complete, the subassembly resembles that shown in FIG.  3 . Connectors  32  are typically connected at each end of the wires  26  to make a wire harness assembly  30 , and one or more of the protectors  20  also facilitate the attachment of the wire harness assembly  30  to a vehicle, as will be described below. 
     As shown in FIG. 4, a strip of single-sided or double-sided tape  34  may be placed on the protectors  20 . The double-sided tape  34  is shown closing off the slot  24  by being installed on the top surface  23 . Now, the wires  26  are received within the protector, and cannot move outwardly of the slots  24 . Single-sided tape can be used simply for closing off the slot  24 . 
     As shown in FIG. 5, the routed part assembly  30  is now placed onto a vehicle panel such as a trim panel  36  by utilizing the double-sided tape  34 . Of course, other attachment methods may be utilized. The present invention thus facilitates the attachment of a wire harness or other routed part onto a trim panel, but does not require any separate attachment structure to be formed onto the trim panel. In addition, the wire harness and protector can be assembled in a single location and then simply attached to the trim panel. These are significant improvements in the assembly and cost of wire harness and trim panel assemblies. 
     FIG. 6 shows an alternative embodiment wherein the protectors  20  are initially placed onto the trim panel  36 , such as by double-sided tape  38 . In this embodiment, the double-sided tape  38  is placed on the bottom surface  27  remote from the slot  24 . Now, the slot  24  is still capable of being opened after the protector  20  has been assembled onto the trim panel  36 . The wires  26  may now be inserted through the slots  24  into the apertures  22 , and thus secured to the protectors  20 , and to the trim panel  36 . Again, this simplifies the assembly of a wire harness or other routed part onto a trim panel over the prior art. 
     FIG. 7 shows an alternative embodiment protector  40  wherein there are secondary apertures  42  formed adjacent to and secondary slots  44  extending from the bottom surface  27 . When the protector  40  is attached to a trim panel with the top surface  23  abutting the trim panel, the secondary apertures  42  and slots  44  will allow the attachment of subsequent wires, such as aftermarket wires. The wires may be moved through the slots  44  into the apertures  42  as in the above embodiments. 
     FIG. 8 shows another embodiment protector  46 , which is provided with an aperture  48  having a minor diameter “dl” and a major diameter “d 2 ”. As can be appreciated, the major diameter “d 2 ” is much greater than the minor diameter “dl”. A plurality of wires  50  has a relaxed generally cylindrical diameter “d 3 ”. The bundle of wires  50  is inserted through a slot  51  and into the aperture  48 . As shown, once the protector  46  has closed the slot  51 , the bundle of wires  50  is squeezed to a new generally oval shape  52 . The oval shape  52  is such that the bundle of wires no longer has the diameter “d 3 ” in the “dl” minor diameter direction of the aperture  48 . However, the bundle of wires has a diameter that is greater than “d 3 ” in the major diameter “d 2 ” direction. This embodiment is particularly useful in applications that are particularly space sensitive in one dimension, but not in the other. That is, if only a small amount of space is available in the minor diameter direction, this invention will allow the use of the wire harness protector and wire harness assembly in such a way that the wire bundle is reduced in size in the minor diameter permitting the best use of the small amount of available space. 
     FIG. 9 shows another embodiment wherein a vehicle panel such as a floor board  54  has a downwardly extending ditch  56  formed therein. The wire harness protector  20  is shown installed with the top surface  23  and the slot  24  abutting a bottom wall  58  of the ditch  56 . The bottom surface  27  of the protector  20  underlies carpeting  60 , such as typically found covering a vehicle floor. The protector  20  thus provides support to the carpeting  60 , and protects the wires  26  or other routed parts as received within the protector  20 . 
     FIG. 10 is a top view of a vehicle incorporating this aspect of the invention. As shown, the floorboard  54  has two ditches  56  receiving a plurality of the protectors  20 . The wires (not shown) thus extend through the ditches  56  and through the spaced wire harness protectors  20 . The protectors  20  are preferably located in locations where there is likely to be the application of an occupant&#39;s foot or cargo which might otherwise damage the routed part assembly  30 . 
     FIG. 11 shows yet another feature of the present invention. In some applications, it may not be necessary to have the wires in both of the ditches  56 . As an example, a vehicle may be prepared such that it can be easily modified for either right hand or left hand driving applications. Such a vehicle might not need wires in one of the two ditches dependent upon the application. 
     FIG. 11 shows another embodiment wire harness protector  62  having a solid body that will provide the support to the carpet, occupant&#39;s feet, and cargo but does not have an aperture for receipt of the bundle of wires. 
     FIG. 12 shows another alternative routed part protector  70  having a central aperture  72  extending between end surfaces  71  and a slot  74  extending from a top surface  73  into the aperture  72 . The protector  70  has a body of preferably generally trapezoidal cross-sectional shape with side walls  75  extending outwardly from the top surface  73  to an opposed bottom surface  77 . The protector  70  is inverted in a ditch  64  formed in the vehicle floorboard  54 . The ditch  64  has rounded contours in contrast to the ditch  56  shown in the FIG.  9 . The body of the protector  70  is similarly rounded. A pair of notches or grooves  79  are formed in the side walls  75  adjacent the bottom surface  77  and extend generally parallel to the central aperture  72  between the end walls  71 . The grooves  79  facilitate the manual outward bending of the side walls  75  during insertion of wires (not shown) through the slot  74  and into the aperture  72  by providing an easily graspable formation. As shown, the cross-sectional area of the central aperture  72  is maximized. 
     FIG. 13 shows yet another embodiment protector  80  similar in exterior shape to the protector  70  shown in FIG.  12 . The protector  80  has a smaller cross-sectional area central aperture  82  extending between end surfaces  81  and a slot  84  extending from a top surface  83  into the aperture  82 . The protector  80  has a body with side walls  85  extending outwardly from the top surface  83  to an opposed bottom surface  87  and is shown inverted in the ditch  64  formed in the vehicle floor board  54 . A pair of notches or grooves  89  are formed in the side walls  85  adjacent the bottom surface  87  and extend generally parallel to the central aperture  82  between the end walls  81  to facilitate the outward bending of the side walls  85  during insertion of wires (not shown) through the slot  84  and into the aperture  82 . A secondary aperture  90  is formed in the body extending generally parallel to the aperture  82  and being open to the bottom surface  87  through a secondary slot  91 . Also formed in the body of the protector  80  are two voids  92  extending between the end walls  81  on either side of and generally parallel to the apertures  82  and  90 . The voids  92  facilitate the bending of the side walls  85  during insertion of the wires (not shown) and reduce the amount of material required to form the protector. 
     FIG. 14 shows an additional embodiment of the protector  100  of the present invention. Protector  100  has a central aperture  102  extending between end surfaces  104  and a slot  106  extending from a top surface  108  into the aperture  102 . Protector  100  has a body of preferably generally trapezoidal cross-sectional shape with side walls  110  extending outwardly from the top surfaced  108  to an opposed bottom surface  107 . The protector is inverted in a ditch  64  formed in the vehicle floor  54 . A first and second secondary aperture  112  and  114  is formed in the body extending generally parallel to aperture  102  and being open to the bottom surface  107  through a first and second secondary slot  116  and  118 . It should be appreciated that forming secondary slots  116  and  118  in the bottom surface facilitates the bending of side walls  110  during insertion of the routed parts into aperture  102 . Secondary slot  116  and  118  can be utilized to receive after market routed parts for articles such as CD changers. 
     Several embodiments of the present invention have been disclosed; however, a worker of ordinary skill in the art would recognize that certain modifications come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention. 
     In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiment. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.