Braided Wiring Harness with Rigid Dual-End Shielding
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Solution Overview
Problem
Existing wiring harnesses, such as those described in U.S. Pat. No. 6,439,929, may still experience excessive strain and inadequate environmental protection due to a taut braided shield or shrink tube that only connects at one end, leading to potential arcing and failure under tensile stress and impact.
Innovation Solution
A wiring harness design featuring a braided covering rigidly connected to both electrical devices with a heat shrink tube, providing additional layers of protection and tensile strength, where the braided material deforms less than the conducting wires, and the heat shrink tube connects the wires to the devices, distributing stress and minimizing strain on soldered joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a braided shield is used to provide environmental protection and strain relief, then robustness is improved, but excessive strain may still occur within the wires due to taut length or deformation
Solution Approach 1:
The braided covering is designed with dynamic deformation characteristics that allow it to stretch and absorb tensile forces. The braid structure inherently provides flexibility while maintaining strength, allowing the covering to dynamically respond to mechanical stresses and protect the internal wires from excessive strain.
Solution Approach 2:
The wiring harness employs a composite structure combining the braided covering material with the internal conducting wires. The braided covering acts as an outer protective layer with different mechanical properties than the inner wires, creating a composite system where the outer layer absorbs stress while the inner wires remain protected.
2Ease of manufacture
If a shrink tube is used to connect the braided shield to the backshell, then assembly is simplified, but extensive tensile strains are induced within the wire
Solution Approach 1:
The braided covering functions as a flexible protective shell that can deform under tensile loads. Unlike rigid connections, the flexible braid structure allows for stress distribution and absorption, reducing the transmission of tensile forces to the internal wires while maintaining connection integrity.
3Ease of manufacture
If the shrink tube terminates at the end of the backshell, then manufacturing is simplified, but environmental protection and strain relief are minimal
Solution Approach 1:
The braided covering is installed and secured in advance before final assembly steps. The covering is positioned to extend beyond the backshell end, providing preliminary protection to the wire exits and connection points before the harness is put into service, ensuring environmental protection is already in place.
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 significantly reduces the likelihood of arcing and enhances impact resistance and tensile strength by distributing stress through the braided material and heat shrink tube, minimizing strain on conducting wires and protecting against disconnection and damage.
Implementation Method 1
a heat shrink tube disposed over and connecting the at least one conducting wire to the electrical device
Data Source
AI summary
A wiring harness is disclosed. The wiring harness may have at least one conducting wire having a length direction, a first end, and an opposing second end. The wiring harness may also have a first electrical device connected to the first end of the at least one conducting wire, and a second electrical device connected to the second end of the at least one conducting wire. The wiring harness may further have a braided covering rigidly connected to the first and second electrical devices. The braided covering may be configured to house the at least one conducting wire and deform in the length direction less than the at least one conducting wire.