Wiring Module Layout for Mixed-Voltage Isolation and EMI Suppression

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Solution Overview

Problem

In power distribution apparatuses for electric vehicles, unintentional current paths can form due to the bundling of signal lines with different applied voltages, leading to abnormal current flow and potential electromagnetic coupling issues.

Innovation Solution

A wiring module is introduced, comprising a first insulated wire with a lower voltage and a second insulated wire with a higher voltage, an intervening member, and a connecting member to prevent direct electrical connection between the two wires, thereby suppressing unintentional current paths and electromagnetic noise.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multiple insulated wires with different voltages are bundled together for power distribution, then wiring efficiency and compactness are improved, but unintentional current paths and electromagnetic coupling issues occur

Engineering Contradiction:

Improvewiring efficiencyVSAvoidelectrical isolation

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

A resin-coated wire is introduced as an intermediary component between insulated wires with different voltages. This resin coating acts as an additional insulating barrier that prevents unintentional current paths while allowing the wires to remain bundled together for efficient power distribution.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The insulation structure is segmented into multiple layers: the base insulation layer of each wire and an additional resin coating layer applied to specific wires. This segmentation creates distinct electrical zones that maintain isolation between different voltage levels while preserving bundled configuration.

Inventive Principle:

Principle #1Segmentation

2Area of stationary object

If insulated wires with different voltages are placed close together for compact design, then space utilization is improved, but electromagnetic coupling and noise interference increase

Engineering Contradiction:

Improvespace utilizationVSAvoidelectromagnetic noise

Core Design Contradiction:

Area of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The resin coating serves as a mediating layer that reduces electromagnetic coupling between adjacent wires with different voltages. This intermediate resin layer acts as both a mechanical binder and an electromagnetic shield, allowing compact wiring while reducing noise interference.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If additional insulation measures are added to prevent unintentional current paths, then electrical safety is improved, but device complexity and manufacturing difficulty increase

Engineering Contradiction:

Improveelectrical safetyVSAvoidmanufacturing simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The resin coating process combines multiple functions into a single manufacturing step: it provides additional insulation, acts as a binder for the wire bundle, and offers environmental protection. This merging of functions achieves enhanced electrical safety without proportionally increasing manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The resin coating serves multiple purposes simultaneously: electrical insulation between different voltage levels, mechanical binding of the wire bundle, and environmental sealing. This multi-functionality reduces the need for separate components and simplifies the overall manufacturing process.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12187203B2Wiring module and power distribution apparatus having the same

Publication Date: 2025.01.07 DENSO CORP

AI summary

A low voltage signal line and a high voltage signal line are connected to a power distribution ECU which controls charging and discharging of an assembled battery. A base portion and a shield member are interposed between the low voltage signal line and the high voltage signal line having different applied voltages. These signal lines and the base are connected by a connecting member.