Conductive Wire with Variable Insulation Thickness for Heat Dissipation
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Solution Overview
Problem
Conductive wires used in vehicle wire harnesses have a large diameter, which hinders their mountability and heat dissipation, particularly in vehicles like hybrid and electric cars.
Innovation Solution
A conductive wire configuration with a rigid single-core wire and a flexible twisted wire, where the rigid wire has a thinner insulating coating than the flexible wire, allowing for a smaller diameter and improved heat dissipation through direct contact with a metal external cover member at bent portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the wall thickness of the first insulating coating is reduced to decrease the diameter of the rigid wire, then the diameter of the conductive wire is reduced, but the insulation performance may deteriorate
Solution Approach 1:
The patent applies different wall thicknesses to different insulating coatings based on their functional requirements. The first insulating coating has a smaller wall thickness (0.01-0.06 times the core wire diameter) optimized for heat dissipation, while the second insulating coating has a larger wall thickness (0.05-0.15 times the core wire diameter) optimized for insulation. This local differentiation resolves the contradiction by providing adequate insulation where needed while minimizing diameter for heat dissipation efficiency.
Solution Approach 2:
The patent uses composite insulating coating structures with different material properties and thicknesses. The first insulating coating uses materials with good heat dissipation properties (such as fluororesin or polyolefin) with thinner walls, while the second insulating coating uses materials with excellent insulation properties (such as cross-linked polyethylene) with thicker walls. This composite approach allows simultaneous optimization of both heat dissipation and insulation performance.
2Volume of moving object
If a single-core rigid wire is used instead of a twisted flexible wire, then the diameter of the conductive wire is reduced, but the flexibility deteriorates
Solution Approach 1:
The conductive wire is segmented into two distinct parts: a rigid single-core wire portion for maintaining small diameter and structural stability, and a flexible twisted wire portion for providing flexibility and ease of installation. This segmentation allows each portion to be optimized for its specific function, resolving the contradiction between diameter reduction and flexibility requirements.
Solution Approach 2:
The patent introduces dynamic characteristics by combining a rigid single-core wire with a flexible twisted wire portion. The twisted wire portion can dynamically adapt to bending and routing requirements during installation and operation, while the single-core rigid portion maintains its structural integrity and small diameter. This dynamic combination resolves the contradiction between rigidity and flexibility.
3Volume of moving object
If the diameter of the conductive wire is reduced to improve mountability, then the heat dissipation capability deteriorates
Solution Approach 1:
The patent changes the parameter of insulating coating wall thickness to optimize heat dissipation. By reducing the wall thickness of the first insulating coating to a specific range (0.01-0.06 times the core wire diameter), heat can more efficiently transfer from the core wire through the insulating coating to the external cover member, improving heat dissipation capability while maintaining the reduced diameter for better mountability.
4Reliability
If the wall thickness of the second insulating coating is increased to improve insulation performance, then the diameter of the conductive wire increases
Solution Approach 1:
The patent applies the local quality principle by differentiating the wall thickness requirements for different insulating coatings. The second insulating coating, which provides the primary insulation barrier, is given a sufficient wall thickness (0.05-0.15 times the core wire diameter) to ensure adequate insulation performance. Meanwhile, the first insulating coating is kept thinner for heat dissipation, creating a localized optimization that balances insulation requirements with overall diameter constraints.
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 reduces the diameter of the conductive wire and wire harness, enhancing vehicle mountability and heat dissipation performance by efficiently transferring heat from the rigid wire to the external cover member.
Implementation Method 1
heat from the rigid wire can be directly transferred through this contact portion to the external cover member
Data Source
AI summary
An object of the description is to provide a conductive wire with a small diameter. A conductive wire configured to be arranged in a vehicle and electrically connect electrical devices includes: a rigid wire having a first core wire, and a first insulating coating that covers an outer circumference of the first core wire; and a flexible wire having a second core wire that is superior to the first core wire in terms of flexibility and is connected to an end of the first core wire, and a second insulating coating that covers an outer circumference of the second core wire. A wall thickness T1 in a radial direction of the first insulating coating of the rigid wire is smaller than a wall thickness T2 in a radial direction of the second insulating coating of the flexible wire.