Conductive Tube Extensions for Welding Heat Shield

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional electromagnetic shield components risk damaging electrical wires during welding due to direct heat exposure and potential sputtering, as wires are enclosed within half tube members before welding, which can lead to damage and interference with the wire harness's internal space efficiency.

Innovation Solution

The electromagnetic shield component features a conductive tube with inwardly extending radial extensions on one half tube, creating gaps between the welds and the extensions, which absorb heat and sputter, preventing wire damage, while the extensions' leading end surfaces guide and secure the other half tube during welding, maintaining processability and space efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If electrical wires are enclosed by half tube members before welding, then the wires are protected during assembly, but the wires are damaged by heat and sputter during welding

Engineering Contradiction:

Improvewire protection during assemblyVSAvoidheat and sputter damage to wires

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The inner circumferential surface of the first half tube is segmented with extensions that create gaps between the weld zone and the wire enclosure space. These extensions divide the internal space into protected and welding zones, preventing harmful factors from reaching the wires while maintaining structural integrity during assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The extensions act as an intermediary barrier between the welding process and the electrical wires. By positioning extensions to face the welds, they intercept heat and sputter before these harmful factors can directly contact the wires, thus protecting the wires while allowing the welding process to proceed.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If extensions are added to the half tube, then wire protection is improved, but the internal space of the tube is reduced

Engineering Contradiction:

Improvewire protection during weldingVSAvoidinternal space of the tube

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The extensions are provided locally at specific positions on the inner circumferential surface where welding occurs, rather than uniformly throughout. This localized approach provides protection exactly where needed (facing the welds) while minimizing the overall volume reduction of the internal space, allowing adequate room for wires in non-welding zones.

Inventive Principle:

Principle #3Local quality

3Reliability

If extensions extend inward toward the second half tube, then heat and sputter are blocked, but the extensions may interfere with wire insertion

Engineering Contradiction:

Improveheat and sputter shieldingVSAvoidwire insertion into the tube

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The extensions extend partially inward toward the second half tube, providing sufficient shielding for heat and sputter protection without fully blocking the internal space. The extensions are positioned and sized to create gaps that allow wire insertion while still intercepting harmful factors from the welding process.

Inventive Principle:

Principle #16Partial or excessive action

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

This configuration effectively prevents electrical wire damage from heat and sputtering during welding, ensures secure assembly, and optimizes the internal space usage of the shield component, maintaining the wire harness's integrity and efficiency.

Implementation Method 1

heat (energy) supplied from a heat source (an energy source) when the ends in the circumferential direction are welded to each other is prevented from being directly supplied to the electrical wire

Methodology Applied

Scientific EffectHeat absorption: Absorption (physical)

Implementation Method 2

sputter that may occur when welding is performed can be received by the extensions

Methodology Applied

Scientific EffectSputter: Sputtering

Data Source

PatentUS10701846B1Electromagnetic shield component and wire harness

Publication Date: 2020.06.30 AUTONETWORKS TECH LTD

AI summary

An electromagnetic shield component that includes a tube that is electrically conductive and into which an electrical wire is to be inserted, wherein the tube includes a first half tube that has a shape of a half tube, a second half tube that has a shape of a half tube, and welds where both ends of the first half tube in a circumferential direction and both ends of the second half tube in the circumferential direction are welded to each other, an inner circumferential surface of the first half tube is provided with extensions that extend inward from the inner circumferential surface of the first half tube, in a radial direction of the tube, toward the second half tube, and portions of the extensions that face the welds in the radial direction are provided such that gaps are formed between the portions and the welds.