Planar Wiring Harness Assembly for EMI Isolation and Crosstalk Control
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Solution Overview
Problem
Existing wiring harness assemblies lack an efficient and integrated solution for combining electrical power, signal, and data channels in a flexible planar package, often resulting in inadequate electrical isolation and susceptibility to electromagnetic interference (EMI) and crosstalk.
Innovation Solution
A wiring harness assembly featuring a lamination process of polymeric substrates with encapsulated conductors, electromagnetic shields, and dielectric materials to provide electrical isolation and EMI protection, while allowing for flexible distribution of power, signal, and data channels in a single flexible planar package.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple conductors are bundled together in traditional wiring harnesses, then electrical power and signal channels can be transmitted, but electrical isolation between conductors is inadequate and susceptibility to EMI and crosstalk increases
Solution Approach 1:
The wiring harness is segmented into multiple independent planar cable layers, each containing specific conductors. This segmentation allows each layer to be independently shielded and isolated, preventing crosstalk and EMI between different conductor groups while maintaining organized power and signal channel distribution.
Solution Approach 2:
Electromagnetic shields are nested within the planar cable structure, positioned between conductor groups. This nested configuration provides internal EMI protection without increasing the overall external dimensions of the wiring harness, effectively isolating adjacent conductors while maintaining a compact design.
Solution Approach 3:
The wiring harness transitions from traditional three-dimensional random conductor bundling to a structured two-dimensional planar configuration. This dimensional change enables systematic spacing, shielding, and routing of conductors, improving electrical isolation and reducing EMI susceptibility through controlled geometric arrangement.
2Reliability
If conductors are arranged in a flexible planar package with electromagnetic shields and dielectric materials, then electrical isolation and EMI protection are improved, but device complexity increases
Solution Approach 1:
Multiple functional elements are merged into integrated planar cable assemblies. Conductors, dielectric materials, and electromagnetic shields are combined into unified planar structures that can be manufactured as single units, reducing assembly complexity while maintaining EMI protection and electrical isolation benefits.
Solution Approach 2:
The planar cable structure serves multiple functions simultaneously: it provides conductor support, electrical isolation, EMI shielding, and mechanical flexibility. This multi-functionality reduces the need for separate protective components, simplifying the overall structure while achieving comprehensive protection.
3Ease of manufacture
If traditional wiring harnesses are used without integrated shielding, then manufacturing is simpler, but susceptibility to electromagnetic interference and crosstalk increases
Solution Approach 1:
Electromagnetic shields and dielectric materials are pre-integrated into the planar cable structure during manufacturing, before the wiring harness is installed in the final application. This preliminary action ensures EMI protection is built-in from the start, eliminating the need for separate shielding installations and simplifying the overall manufacturing process.
Solution Approach 2:
The wiring harness uses composite structures combining conductive materials, dielectric materials, and electromagnetic shield materials in integrated planar configurations. These composite constructions provide both mechanical integrity and EMI protection, achieving enhanced performance without significantly complicating manufacturing through standardized composite material processing.
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 effectively inhibits short circuits, crosstalk, and EMI, ensuring reliable transmission of electrical power, signals, and data communications with improved mechanical and thermal properties, enhancing the overall performance and durability of the wiring harness.
Implementation Method 1
a second conductor (24B, 26E) of the second plurality of separated conductors (20B) formed in a second dielectric material layer (34)
Implementation Method 2
Each of the first and second electromagnetic shields (28A, 28B, 36A, 36B, 42A, 42B) includes a conductive foam material (41)
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A wiring harness assembly (10) includes a first flexible planar wire cable (48). The first flexible planar wire cable (48) has a first plurality of separated conductors (20) formed in a first insulating layer. The first insulating layer includes a first flat exterior surface (52). The first flat exterior surface (52) defines first apertures (54) that expose at least a portion the first plurality of separated conductors (20). The first apertures (54) are sized, shaped, and arranged such that arranging a second flat exterior surface (52) of a second flexible planar wire cable (50) in contact with the first flat exterior surface (52) enables an electrical connection (60) between the first plurality of separated conductors (20) and a second plurality of separated conductors (20) formed in a second insulating layer of the second flexible planar wire cable (50).