High-Voltage Wire Harness Segmented Shielding
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Solution Overview
Problem
Conventional high-voltage wire harnesses with shielding performance are costly due to the extensive use of expensive flexible shielding members across the entire length, which is unnecessary in regions where flexibility is not required.
Innovation Solution
The wire harness employs rigid wires with a metal shielding case in inflexible regions and flexible wires with a flexible shielding member in flexible regions, with the flexible shielding member used only at the ends, reducing overall cost and maintaining electromagnetic noise protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If flexible shielding members are used over the entire length of the wires, then electromagnetic noise shielding performance is improved, but the cost of the wire harness becomes very high
Solution Approach 1:
The patent applies different shielding solutions to different regions of the wire harness based on local requirements. Rigid wires with metal shielding cases are used in regions where flexibility is not required (such as straight installation paths), while flexible wires with flexible shielding members are used only in regions where flexibility is needed (such as bent installation paths). This local differentiation maintains electromagnetic noise shielding performance while significantly reducing the overall cost by avoiding the use of expensive flexible shielding members throughout the entire length.
2Object-affected harmful factors
If shielded wires are used over the entire length of the installation path, then electromagnetic noise protection is improved, but the cost is very high
Solution Approach 1:
The wire harness is segmented into different types of wires based on installation path requirements. The patent divides the installation path into straight regions (where rigid wires are sufficient) and bent regions (where flexible wires are needed). By segmenting the wire harness in this manner and applying shielding only where necessary, the patent maintains electromagnetic noise protection while reducing costs through the strategic use of expensive shielded components only in critical flexible regions.
3Ease of manufacture
If rigid wires with metal shielding case are used in inflexible regions, then cost is reduced and shielding performance is maintained, but flexibility is lost
Solution Approach 1:
The patent applies different structural qualities to different regions of the wire harness. Rigid wires with metal shielding cases are specifically deployed in straight installation path regions where flexibility is not required, while flexible wires are used in bent installation path regions where flexibility is essential. This local quality differentiation ensures that each region receives the appropriate level of flexibility and shielding, optimizing both cost and adaptability.
4Ease of manufacture
If flexible shielding members are used only at the ends, then cost is significantly lowered, but shielding coverage is reduced
Solution Approach 1:
The patent segments the shielding application into two distinct approaches: metal shielding cases for rigid wires in straight regions, and flexible shielding members for flexible wires in bent regions. This segmentation allows the patent to achieve comprehensive shielding coverage not by reducing shielding, but by diversifying shielding methods to match the specific requirements of each region, thereby maintaining overall shielding effectiveness while significantly reducing costs.
Data Source
AI summary
That portion of a wire harness, corresponding to an installation path region E1 where a cable is not required to have flexibility, includes rigid wires 1 each having a single conductor 1a, and a metal shielding case 2 covering outer peripheries of the rigid wires 1. Each of those portions of the wire harness, corresponding respectively to installation path regions E2 where the cable is required to have flexibility, includes flexible wires 4, and a flexible shielding member 5 covering outer peripheries of the flexible wires 4. Conductors 4a of the flexible wires 4 are connected to the conductors 1a of the rigid wires 1, and the metal protector 2 is connected to the flexible shielding members 5.