Monolithic Electrical Harness with Adaptive Composite Rigidity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current electrical connection harnesses for avionic systems face challenges in reducing component count and weight while maintaining protection against severe environmental stresses, mechanical, thermal, and hygrometric stresses, and Electromagnetic Interference (EMI), often requiring multiple components and references.
Innovation Solution
A monolithic electrical connection harness is developed using a flexible elastomer matrix with adaptive reinforcement layers and a metallic sheath for EMI protection, integrated with carbon and aramid fibers, and an anti-adherent film to manage stress levels and prevent adhesion, allowing for easy replacement and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate protective components (flexible conduits, rigid conduits, transition fittings) are used to protect the harness, then the protection against environmental stresses and EMI is improved, but the weight and device complexity increase significantly
Solution Approach 1:
The patent combines multiple separate protective components (flexible conduits, rigid conduits, transition fittings, branch fittings) into a single monolithic protective sheath made of composite material. This integrated structure eliminates the need for multiple discrete parts while maintaining comprehensive protection against environmental stresses, mechanical damage, and EMI throughout the entire harness length.
Solution Approach 2:
The protective sheath is constructed using composite materials that integrate the protective functions previously distributed across multiple components. The composite structure provides both mechanical protection and EMI shielding in a single element, reducing component count while enhancing overall protection capability.
2Reliability
If multiple separate protective components are used to ensure protection in severe conditions, then the reliability is improved, but the weight of the harness increases
Solution Approach 1:
By merging multiple protective functions into a single integrated sheath, the patent eliminates the cumulative weight of separate components. The monolithic structure provides comprehensive protection against severe environmental conditions while being lighter than the assembly of discrete protective elements.
Solution Approach 2:
The use of composite materials allows the protective sheath to achieve high strength-to-weight ratio, providing robust protection in severe conditions while minimizing the overall weight of the protective assembly compared to traditional metal or multi-component constructions.
3Device complexity
If a monolithic protective structure is used to reduce component count, then the device complexity is reduced, but the adaptability to different rigidity requirements along the harness is worsened
Solution Approach 1:
The protective sheath incorporates localized reinforcement zones with varying fiber orientations and densities along its length. This allows different sections of the monolithic structure to have tailored rigidity characteristics suited to specific harness segments, maintaining adaptability while preserving the integrated design.
Solution Approach 2:
The composite construction enables spatial variation in material properties within the monolithic sheath. By adjusting fiber placement, density, and orientation in different regions, the structure achieves locally optimized rigidity while remaining a single integrated component.
4Reliability
If traditional protective assemblies with multiple components are used, then the protection function is achieved, but the routing allowances are excessively large
Solution Approach 1:
The integrated protective sheath eliminates gaps and transition zones between separate components, allowing the harness to be routed in tighter spaces. The continuous monolithic structure provides protection without requiring the additional clearance that would be needed for multiple discrete components and their connections.
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 provides a lightweight, adaptable, and robust monolithic harness that effectively manages stress and EMI, reducing the number of components and references needed, while ensuring protection in severe conditions, and is easily interchangeable.
Implementation Method 1
a matrix of flexible protective material of the elastomer seal type
Implementation Method 2
stiffening the matrix by draping reinforcements of the type adapted to the desired function (robustness, rigidity, type of protection)
Implementation Method 3
a metallic sheath for EMI protection, integrated with carbon and aramid fibers
Implementation Method 4
an anti-adherent film to manage stress levels and prevent adhesion
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a monolithic electrical connection harness (1) having an adapted rigidity traveling along a determined path, comprising a flexible insulating casing (2a to 2c) inserting shielded electrical connection cables (C1 to C3) to constitute a bundle (F1 to F3), means (S1 to S3) for holding the ends (Z1 to Z3) of the flexible casing (2a to 2c) on rear connections (R1 to R3) integrating the end zones (E1 to E3) of the cables (C1 to C3) In this harness (1), a reinforcing sheath (6) surrounds the cable bundle (F1 to F3) and is made up of one or more layers (61 to 63) of composite material made from a flexible matrix in polymer material in which a ply of fibers for reinforcing in robustness and/or stiffness is draped along the cable bundle (F1 to F3), the reinforcing fibers being assembled in each ply in a shape chosen from between a unidirectional web, a multidirectional web and a fabric of wires formed from braided fibers.