Laminated Flat Conductor Wiring Member for Vehicle Routing
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Solution Overview
Problem
Conventional wiring members, particularly thick wires used in vehicles with rear batteries, are difficult to bend and insulate, making it challenging to route them along body panels and reducing the flexibility in vehicle compartment design.
Innovation Solution
A laminated flat conductor wiring member with insulating sheet members between flat conductors, allowing for easy bending and insulation, and a manufacturing method that includes lamination, insulation, and powder coating to form a thin insulating layer, enabling the wiring member to conform to complex surfaces and reduce routing space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional thick wires are used for transmitting electricity, then the electrical transmission function is achieved, but the wiring member becomes difficult to bend and route along body panels
Solution Approach 1:
The conductor is divided into multiple flat conductor layers stacked in the thickness direction, with insulating sheet members interleaved between them. This segmentation allows the wiring member to be more flexible and easier to bend while maintaining adequate electrical transmission capability through the combined cross-sectional area of multiple layers.
Solution Approach 2:
The invention transitions from conventional circular cross-section wires to a flat, multi-layered structure where conductors are arranged in the thickness direction rather than being bundled laterally. This dimensional reorganization reduces the width and improves bendability while maintaining electrical transmission through the stacked configuration.
2Reliability
If conventional extrusion molding is used to cover conductors with insulating material, then insulation is achieved, but the process requires the conductor to be soft and difficult to bend
Solution Approach 1:
Insulating sheet members are pre-positioned between the flat conductor layers during assembly, providing insulation before the extrusion molding process. This preliminary insulation allows the conductor assembly to be more flexible while still achieving reliable insulation, as the rigid insulating sheets maintain their position and the extrusion then seals the overall structure.
Solution Approach 2:
The wiring member employs a composite structure combining flat conductors, rigid insulating sheet members, and an outer insulating layer from extrusion molding. This multi-material approach allows each component to fulfill its function optimally: the sheet members provide structural insulation between layers, while the extrusion provides external protection and seals the assembly.
3Reliability
If thick wires are used to ensure adequate current carrying capacity, then electrical transmission is reliable, but the routing space in vehicle compartment increases
Solution Approach 1:
The invention redistributes the conductor cross-sectional area from a wide lateral arrangement to a stacked configuration in the thickness direction. Multiple flat conductor layers are arranged vertically with insulating sheets between them, converting a wide profile into a thinner, more compact structure that maintains adequate current carrying capacity through the combined area of all layers.
Solution Approach 2:
The conductor is segmented into multiple flat layers that can be efficiently stacked and compacted in the thickness direction. This segmentation allows the total conductive material to be concentrated in a thinner profile compared to conventional bundled wires, reducing the routing space occupation while maintaining electrical transmission reliability.
Data Source
AI summary
A wiring member includes a laminated flat conductor and an insulating layer provided around the laminated flat conductor. The laminated flat conductor includes a plurality of flat conductors laid on each other in a thickness direction of the laminated flat conductor, and insulating sheet members each of which is interposed between and electrically insulates adjacent ones of the plurality of flat conductors.