Conductive Resin Wire Harness Shielding
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Solution Overview
Problem
The weight of high voltage wire harnesses in hybrid and electric vehicles is increased due to the use of long metal pipes for electromagnetic shielding, which hinders weight reduction in vehicles.
Innovation Solution
A wire harness with a pipe-like protective member made of conductive resin composition, covered with an insulating resin coating, and connected with braids for shielding, reducing the need for external protectors and metal components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a long metal pipe is used for electromagnetic shielding, then electromagnetic shielding effect is ensured, but wire harness weight is increased
Solution Approach 1:
The patent applies composite materials by combining resin (polymer matrix) with conductive fillers (carbon fiber, metal powder, or conductive polymer) to create a protective member that provides both electromagnetic shielding and structural protection. This composite approach replaces traditional metal pipes while maintaining shielding effectiveness through the conductive network formed by the filler particles within the resin matrix.
Solution Approach 2:
The patent changes the material parameters by transitioning from pure metal to resin-based composite materials. By adjusting the conductive filler content, particle size, distribution, and resin matrix composition, the shielding effectiveness and mechanical properties can be optimized to achieve adequate electromagnetic protection with reduced weight compared to solid metal pipes.
2Weight of moving object
If conductive resin composition is used for protective member, then weight is reduced, but electromagnetic shielding effect may be compromised
Solution Approach 1:
The conductive resin composition is a composite material combining polymer resin with conductive fillers such as carbon fiber, metal powder, or conductive polymer particles. This composite structure provides both the lightweight advantage of resin and the electromagnetic shielding capability of conductive materials through the formation of a conductive network within the resin matrix.
Solution Approach 2:
The patent applies local quality by concentrating conductive filler particles in specific regions or configurations within the resin matrix to optimize shielding effectiveness. The conductive fillers are distributed or arranged to create effective shielding paths where needed, while maintaining the overall lightweight resin-based structure.
3Strength
If insulating resin coating is applied over conductive protective member, then protection from external force is improved, but complexity of structure increases
Solution Approach 1:
The patent merges multiple functions into a single integrated protective member structure. The conductive resin composite itself is formulated to provide both electromagnetic shielding and mechanical protection properties, eliminating the need for separate metal shielding layers and external protectors. The insulating resin coating is integrated as part of the same molded structure, creating a unified component that performs multiple protective functions simultaneously.
Solution Approach 2:
The protective member made of conductive resin composition serves multiple functions: electromagnetic shielding through its conductive properties, mechanical protection through its structural integrity, and electrical insulation through the resin matrix and outer coating. This multi-functional design eliminates the need for multiple separate components, reducing overall structural complexity despite the enhanced protective capabilities.
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 provides effective electromagnetic shielding while reducing the weight of the wire harness and vehicle, improving protection, manufacturing efficiency, and lowering costs by eliminating the need for external protectors and reducing the number of components.
Implementation Method 1
a pipe-like protective member which collectively covers and shields the one or more conducting paths
Implementation Method 2
an insulating resin coating that is formed of resin composition having a property of insulating
Data Source
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AI summary
A wire harness (10 to 13, 31) includes one or more conducting paths (19), a protective member (20) that is formed in a pipe shape, and accommodates the one or more conducting paths (19) in the protective member (20) to shield a electromagnetic wave emitted from the one or more conducting paths (19). The protective member (20) is formed of resin composition that has conductivity.