High Voltage Conductive Wire with Coaxial Metallic Pipe Conductor
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Solution Overview
Problem
High voltage conductive wires used in hybrid and electric vehicles require thick wires, leading to large covering members when metallic pipes are used, making it impossible to achieve sufficient distance from the ground, thereby restricting material variation and causing potential damage.
Innovation Solution
A high voltage conductive wire configuration using a single wire for both the plus and minus circuits, with a metallic pipe as the conductor, and an electromagnetic shield member between the wire and the covering member, allowing for a reduced diameter and improved manufacturability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If two thick high voltage conductive wires are used for plus and minus circuits, then sufficient conductor cross-sectional area is ensured, but the diameter of the covering member becomes large
Solution Approach 1:
The patent merges the plus circuit and minus circuit into a single coaxial cable structure. The inner conductor carries one polarity while the outer conductor (metallic pipe) carries the opposite polarity, eliminating the need for two separate thick wires. This integration maintains sufficient conductor cross-sectional area for high voltage transmission while dramatically reducing the overall diameter of the covering member.
Solution Approach 2:
The patent employs a nested structure where the inner conductor is positioned within the outer conductor (metallic pipe), with insulating layers between them. This concentric arrangement allows both conductors to be housed within a single compact covering member, reducing the diameter from what would be required for two separate parallel wires while maintaining the necessary conductor cross-sectional area for electrical performance.
2Quantity of substance
If a large diameter covering member is used to accommodate two thick wires, then conductor cross-sectional area is sufficient, but sufficient distance from ground cannot be achieved
Solution Approach 1:
By combining the plus and minus circuits into a single coaxial cable, the overall diameter is reduced, enabling the wire harness to be routed closer to the ground with sufficient clearance. The nested conductor arrangement maintains electrical performance while achieving the required distance from ground for safe installation under vehicle floors.
3Reliability
If metallic pipe is used as covering member, then protection function is ensured, but material variation is restricted
Solution Approach 1:
The patent introduces insulating layers as intermediary elements between the inner conductor and outer conductor, and between the outer conductor and covering member. These insulating intermediaries enable the use of non-metallic covering members (such as resin or plastic pipes) while maintaining electrical insulation and protection functions. The intermediary insulating layers decouple the electrical protection requirement from the material choice, allowing versatility in covering member materials.
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
There is provided a high voltage conductive wire (15) including a first conductor (19), a first insulator (20), a second conductor (22) and a second insulator (23). The first conductor performs as one of a plus pole and a minus pole. The first insulator is provided outside of the first conductor. The second conductor performs as the other of the plus pole and the minus pole, is provided outside of the first insulator, and is formed by a metallic pipe. The second insulator is provided outside of the second conductor so as to cover an outer face of the second conductor. A cross sectional area of the second conductor (22) is set corresponding to a cross sectional area of the first conductor (19).