Shielded Electric Harness With PTFE Corrugated Sheath
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Solution Overview
Problem
Existing electric harness technologies either fail to withstand high temperatures or are too heavy and inflexible to accommodate short radii of curvature, limiting their application in severe temperature and electromagnetic environments.
Innovation Solution
A shielded and sealed electric harness with a tubular structure comprising a textile braid, metal braid for electromagnetic shielding, and a high-temperature PTFE corrugated outer sheath, secured by a heat-shrink endpiece and metal collar, allowing for flexibility and weight reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a tubular structure with PTFE inner sheath, metal braid, and textile braid is used for high-temperature zones (up to 260°C), then temperature resistance is improved, but weight increases and flexibility deteriorates
Solution Approach 1:
The patent changes the material parameters by using PTFE (polytetrafluoroethylene) instead of conventional polymers, which has a higher melting point and can withstand temperatures up to 260°C. This material substitution resolves the temperature resistance issue while the corrugated design maintains flexibility to avoid excessive weight gain
Solution Approach 2:
The outer sheath is designed with a corrugated (undulated) structure instead of a smooth cylindrical form. This corrugated geometry provides flexibility and allows the harness to bend with short radii of curvature, counteracting the stiffness that would otherwise increase weight and reduce flexibility in high-temperature applications
2Temperature
If a tubular structure with PTFE inner sheath, metal braid, and textile braid is used for high-temperature zones (up to 260°C), then temperature resistance is improved, but flexibility deteriorates
Solution Approach 1:
The outer sheath is designed with a corrugated (undulated) structure instead of a smooth cylindrical form. This corrugated geometry provides flexibility and allows the harness to bend with short radii of curvature, counteracting the stiffness that would otherwise increase weight and reduce flexibility in high-temperature applications
Solution Approach 2:
The patent employs a corrugated outer sheath structure that acts as a flexible protective layer. The undulated form allows the sheath to flex and bend without breaking, maintaining ease of operation and installation while still providing the necessary protection against high temperatures and electromagnetic interference
3Ease of manufacture
If a heat-shrink polymer endpiece is used to secure the shielding braid, then ease of assembly is improved, but temperature resistance deteriorates (limited to 150°C)
Solution Approach 1:
The endpiece is constructed as a composite structure combining heat-shrink polymer material with a metal collar or ferrule. The heat-shrink polymer provides ease of assembly through thermal contraction, while the metal collar embedded within or attached to it provides the necessary temperature resistance for high-temperature environments up to 260°C
Solution Approach 2:
The endpiece design features asymmetric material distribution with the heat-shrink polymer forming the outer layer for assembly ease, while the metal collar is positioned internally to provide structural strength and temperature resistance. This asymmetric composite structure optimizes both assembly characteristics and thermal performance
4Temperature
If a mechanical collar is used to hold the end structure, then temperature resistance is improved, but device complexity increases
Solution Approach 1:
The metal collar is merged with the heat-shrink polymer endpiece to form an integrated composite structure. The collar is either embedded within the polymer during manufacturing or attached to it, combining the temperature resistance of metal with the assembly ease of heat-shrink material in a single unified component, thereby reducing overall device complexity
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, flexible, and effective protection for electric wires and cables in both medium and high-temperature zones, simplifying manufacturing and assembly while ensuring electromagnetic shielding continuity.
Implementation Method 1
an endpiece made of a heat-shrink polymer and serving both to protect the end of the shielding braid on the tubular metal or composite connection part and also to connect with the outer sheath of that connection part
Implementation Method 2
an outer sheath of heat-shrink polymer... The outer sheath is made of a material that withstands high temperatures, e.g. PTFE, and its corrugated structure enables it to accept short radii of curvature
Implementation Method 3
a tubular braid surrounding the textile braid and providing electromagnetic shielding
Data Source
AI summary
A shielded and sealed electric harness having conductors housed in a tubular structure providing protection and shielding, the structure being constituted by a tubular inner textile braid, an intermediate metal tubular braid for electromagnetic shielding, and a corrugated outer sheath having its end adhesively bonded to a heat-shrink endpiece for fastening onto a portion of a connector of a branch joint.