Coaxial High-Voltage Cable for Compact EV Wiring Harnesses
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Solution Overview
Problem
Conventional high-voltage wiring harnesses for electric vehicles require significant space and are costly due to the need for large electric wires and complex die-based protectors, limiting flexibility and increasing production time and costs.
Innovation Solution
A high-voltage conductive path with a single core wire for both positive and negative electrodes, surrounded by insulators and a shield member, allowing for a compact, three-layer structure that cancels magnetic fields and reduces noise, enabling easier pathway formation and cost savings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If two large electric wires are arranged parallel to each other to transmit drive-train electrical power, then the high-voltage conductive path can transmit sufficient power, but large space is required
Solution Approach 1:
The patent merges the positive electrode conductor and negative electrode conductor into a single coaxial structure, where the positive conductor is positioned at the center and the negative conductor surrounds it. This combining of two separate parallel wires into one integrated cable reduces the overall space occupation while maintaining the capability to transmit both positive and negative electrical power for drive-train applications
Solution Approach 2:
The patent employs a nested structure where the positive electrode conductor is positioned at the center, surrounded by a first insulator, then the negative electrode conductor, and finally an outer insulator layer. This nested arrangement allows both conductors to be contained within a single compact cable structure, significantly reducing the space required compared to parallel wire arrangements while maintaining adequate power transmission capability
2Power
If two large electric wires are arranged parallel to each other, then the high-voltage conductive path can transmit sufficient power, but the bending direction of the wiring harness is constrained
Solution Approach 1:
By combining the positive and negative conductors into a single coaxial cable structure, the patent creates a more flexible unit that can bend in multiple directions without the constraints of arranging two separate rigid parallel wires. The integrated structure allows the wiring harness to adapt to various routing paths while maintaining adequate power transmission capability
Solution Approach 2:
The patent employs flexible insulator materials that surround the conductors, allowing the entire cable structure to bend and flex as needed. The insulator layers provide electrical isolation while permitting the cable to be routed in various directions, significantly improving the adaptability and bending flexibility of the high-voltage conductive path
3Reliability
If a protector is used to form the pathway of the wiring harness, then the pathway formation is protected, but the cost of the protector increases due to die manufacturing
Solution Approach 1:
The patent merges the pathway formation function and protection function into the high-voltage conductive path itself. The coaxial cable structure is designed to maintain its shape and provide its own protection without requiring a separate protector component, thereby eliminating die manufacturing costs while still ensuring reliable pathway formation and protection
4Reliability
If a protector is used to form the pathway of the wiring harness, then the pathway formation is protected, but the lead time of commencement of work increases
Solution Approach 1:
By integrating the pathway formation and protection functions into the high-voltage conductive path structure itself, the patent eliminates the need for separate protector manufacturing and assembly steps. This reduces lead time significantly while maintaining adequate pathway protection and formation 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 solution saves space, reduces material costs, and simplifies pathway formation, while providing effective shielding and maintaining shape integrity, thus lowering overall costs and production time.
Implementation Method 1
The positive or negative electrode conductor is a single core wire, and has a shape holding function for holding a shape along an arrangement pathway
Implementation Method 2
The positive electrode conductor, the negative electrode conductor and the shield member are substantively constructed with three-layer structure
Data Source
Figure 1A~1C
Figure 1D~2A
Figure 2B
AI summary
A high-voltage conductive path and a wiring harness are provided. The wiring harness includes the high-voltage conductive path having a shape holding function for holding a shape along an arrangement pathway. The high-voltage conductive path includes a positive electrode conductor (18), a first insulator (19) extruded and arranged outside of the positive electrode conductor, a negative electrode (20) arranged outside of the first insulator, a second insulator (21) extruded and arranged outside of the negative electrode conductor, a shield member (22) wrapped outside of the second insulator, first and second sheaths (23, 24) extruded and arranged outside of the shield member. The high-voltage conductive path can save space, and easily perform pathway formation, and reduce cost.