Conductive Path Structure for Collision Safety

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Solution Overview

Problem

High voltage wire harnesses in hybrid and electric motor vehicles are prone to being cut off during collisions, leading to dangerous electrical currents flowing into conductive vehicle components.

Innovation Solution

A conductive path structure with a conductor and covering members, where the conductor has a cut-off facilitating portion and is covered by first and second covering members, preventing exposure of conductor ends when cut, ensuring stability by restricting contact with other members.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a single covering member is used to cover the conductor, then the structure is simple, but when the conductor is cut off, the exposed conductor end can contact other conductive members causing dangerous electrical currents

Engineering Contradiction:

Improvesafety against electrical contactVSAvoidstructure of covering members

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The covering member is divided into a first covering member and a second covering member that are positioned at different ends of the conductor. This segmentation ensures that when the conductor is cut, each covering member remains in place to cover its respective conductor end, preventing electrical contact while maintaining structural simplicity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first covering member and second covering member are nested relative to each other, with one covering member positioned inside or adjacent to the other. This nested arrangement allows both covering members to work together compactly to prevent exposure of conductor ends without adding excessive structural complexity

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If the covering members are fixed rigidly to the conductor, then the position is stable, but when the conductor is cut, the covering members may separate or detach exposing the conductor ends

Engineering Contradiction:

Improveretention of covering membersVSAvoidposition of covering members

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The covering members are designed with dynamic retention mechanisms such as elastic forces, interference fits, or friction-based holding that allow them to remain securely attached to the conductor under normal conditions but maintain their position even when the conductor is cut, preventing exposure while allowing for controlled movement

Inventive Principle:

Principle #15Dynamics

3Manufacturing precision

If no cut-off facilitating portion is provided, then the conductor structure is simple, but the cut position cannot be controlled leading to unpredictable conductor end exposure

Engineering Contradiction:

Improvecontrol of cut positionVSAvoidconductor structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

A cut-off facilitating portion is provided at a specific location on the conductor, creating a localized feature that guides the cut position. This local modification allows precise control of where the conductor will be cut without complicating the overall conductor structure, ensuring predictable coverage by the covering members

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS9330813B2Conductive path structure and wire harness

Publication Date: 2016.05.03 YAZAKI CORP

AI summary

A conductive path structure includes a conductor that includes a first conductive portion and a second conductive portion which are connected to each other through a cut-off facilitating portion, a first covering member that covers the first conductive portion and the cut-off facilitating portion, and a second covering member that covers the second conductive portion and the cut-off facilitating portion. The second covering member covers the cut-off facilitating portion through the first covering member. The second covering member slidably covers the first covering member.