Conductive Wire With Insulated Core And Metal Sheath
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Solution Overview
Problem
Conductive wires in vehicle wire harnesses lack sufficient strength and are prone to degradation in electrical conductivity due to peeling of metal coatings, which affects the reliability of shielding braided members and wire harnesses.
Innovation Solution
A conductive wire configuration featuring a core wire made of insulating reinforced fibers, such as aramid fibers, inserted into a metal pipe sheath member, which enhances strength and reduces the risk of electrical conductivity degradation by avoiding coating peeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal coating is applied to the core wire by vapor deposition, sputter, or plating, then electrical conductivity is achieved, but the sheath member is prone to peeling and degradation in electrical conductivity
Solution Approach 1:
The conductive wire is divided into two independent functional components: a core wire made of insulating reinforced fiber and a separate sheath member made of metal material. This segmentation allows each component to perform its specialized function without compromising the other, eliminating the adhesion problems between coating and substrate.
Solution Approach 2:
The core wire is inserted into the sheath member, creating a nested structure where the insulating core is contained within the conductive sheath. This nested configuration provides mechanical strength and electrical conductivity while avoiding the need for direct bonding between dissimilar materials.
2Reliability
If the sheath member is formed by vapor deposition, sputter, or plating, then electrical conductivity is achieved, but manufacturing complexity increases due to multiple processing steps
Solution Approach 1:
By separating the core wire and sheath member as independent components, the manufacturing process can produce each component separately using optimized methods, then assemble them through simple insertion, reducing overall manufacturing complexity compared to multi-step coating processes.
Solution Approach 2:
The core wire acts as an intermediary structure that provides mechanical support and insulation, allowing the sheath member to be a simple metal tube rather than a complex coated structure, thereby simplifying the manufacturing process.
3Reliability
If a coating structure is used for the sheath member, then electrical conductivity is achieved, but the structure is more complex compared to a fixed layer
Solution Approach 1:
The sheath member is designed as a simple metal tube structure rather than a complex multi-layer coating, achieving electrical conductivity through the inherent properties of the metal material rather than through complex coating structures.
Solution Approach 2:
Instead of applying a thin conductive coating to an insulating core, the invention inverts the approach by using a metal tube as the sheath member, where the metal material itself provides both structural and conductive functions in a simpler configuration.
Data Source
AI summary
Conductive wires that constitute a shielding braided member each include a core wire that is made up of insulating reinforced fibers, and a sheath member that is made of a metal material that covers the outer circumferential surface of the core wire.