Concentric High-Voltage Conduction Path for Space-Saving Routing
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Solution Overview
Problem
The existing high-voltage conduction paths in hybrid vehicles require significant routing space and face constraints in bending, leading to challenges in path formation and potential noise interference due to the parallel arrangement of thick wires.
Innovation Solution
A high-voltage conduction path comprising a positive and negative electrode conductor arranged concentrically, with the negative conductor formed into a cylindrical shape by spirally winding metal wire material, allowing for space savings and flexible path formation, while also providing magnetic and electromagnetic shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two high-voltage conduction paths are routed side by side, then power transmission is achieved, but routing space increases and bending becomes constrained
Solution Approach 1:
The patent combines two separate high-voltage conduction paths (positive and negative circuits) into a single integrated cable structure. The inner conductor and outer conductor are arranged concentrically within the same cable housing, eliminating the need for two separate parallel cables. This merging reduces the routing space from requiring width for two side-by-side cables to requiring only the cross-sectional area of one integrated cable.
Solution Approach 2:
The patent implements a nested configuration where the inner conductor (carrying positive or negative current) is placed inside the outer conductor (carrying return current). The insulator is nested between them, creating a concentric arrangement. This nesting allows both conduction paths to occupy the same spatial envelope, dramatically reducing the routing space required compared to side-by-side placement.
2Reliability
If two thick wires are routed side by side, then power transmission is achieved, but constraint occurs in bending direction
Solution Approach 1:
By merging two rigid thick wires into a single integrated cable with concentric conductors, the patent creates a unified flexible structure. The outer conductor acts as a protective sheath that allows the inner conductor to bend more freely, while the insulator maintains electrical isolation during bending. This combined structure is inherently more flexible than two separate thick wires constrained to bend together.
Solution Approach 2:
The patent enables dynamic bending of the conduction path by allowing the inner and outer conductors to move independently within the cable structure during bending. The concentric arrangement permits rotational and flexural movements that would be constrained in a rigid side-by-side configuration, facilitating easy routing around bends and obstacles.
3Reliability
If two thick wires are routed side by side, then power transmission is achieved, but impact on path formation occurs
Solution Approach 1:
The patent simplifies path formation by manufacturing a single integrated cable containing both conductors rather than assembling two separate cables. The concentric conductor arrangement is built into the cable structure during manufacturing, eliminating the need for complex routing and securing of two separate thick wires along the desired path.
Solution Approach 2:
The flexible concentric cable structure allows for easy adaptation to various routing paths during installation. The cable can be bent, coiled, and routed around obstacles without requiring precise alignment or special handling that would be needed for two separate rigid wires, significantly easing path formation and installation processes.
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 achieves space savings, facilitates path formation, reduces noise interference, and enhances heat management by allowing the outer conductor to absorb and disperse heat, while maintaining electrical stability and shielding effectiveness.
Implementation Method 1
The other conductor is made of a metal wire material and formed into a cylindrical shape by spirally winding the metal wire material
Implementation Method 2
When positive-side current is supplied to the positive electrode conductor and negative-side current is supplied to the negative electrode conductor in a direction opposite to and in parallel with the positive-side current supplied to the positive electrode conductor, magnetic fields that are generated from each of the positive electrode conductor and the negative electrode conductor are cancelled each other
Implementation Method 3
the other conductor can absorb the heat generated in the one conductor and disperse the heat over the whole of the other conductor or can prevent the heat from the outside from being transmitted to the one conductor
Implementation Method 4
a first insulator provided on the outside of the one conductor, the other conductor of the positive electrode conductor and the negative electrode conductor, the other conductor being provided on the outside of the first insulator, and a second insulator provided on the outside of the other conductor
Data Source
Figure 1A~1B
Figure 2
Figure 3A~3B
AI summary
A wiring harness (9) of the present invention is configured to comprise a high-voltage conduction path (15) and a terminal that is provided on an end of the high-voltage conduction path (15). The high-voltage conduction path (15) is provided with: a high-voltage wire (21) that comprises a conductor (19) and a first insulating body (20); a high-voltage spiral wire (22) that is provided so as to cover the high-voltage wire (21); a second insulating body (23) that covers the high-voltage spiral wire (22); an electromagnetic shielding member (24) that is provided so as to cover the second insulating body (23); and a sheath (25) that covers the electromagnetic shielding member (24).