PTFE High-Voltage Harness Coupling for Grounded Watertight Routing
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Solution Overview
Problem
Existing high voltage wiring harness connections in heavy-duty vehicles face issues with high electrical conductivity and inadequate protection against abrasion and temperature fluctuations, particularly when using polypropylene and polyethylene materials.
Innovation Solution
A system utilizing polytetrafluoroethylene tubing for abrasion and temperature insulation, combined with an adapter plate and stainless steel coupling assembly for mechanical and electrical grounding, providing a water-tight seal and electrical circuit completion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polypropylene and polyethylene materials are used for tubing, then the tubing provides adequate mechanical protection, but the electrical conductivity is too high (5-10 Siemens/cm)
Solution Approach 1:
The patent changes the material parameter of the tubing from conventional polypropylene/polyethylene to polytetrafluoroethylene (PTFE), which fundamentally alters the electrical conductivity parameter from 5-10 Siemens/cm to a much lower value, providing adequate electrical insulation while maintaining mechanical protection
Solution Approach 2:
The patent employs PTFE as a specialized material that combines excellent electrical insulation properties with superior mechanical protection capabilities, creating an optimized composite solution that simultaneously addresses both insulation requirements and mechanical protection needs
2Object-affected harmful factors
If conventional tubing materials are used, then the tubing provides basic protection, but protection from abrasion and temperature fluctuations is insufficient
Solution Approach 1:
The patent selects PTFE material which possesses exceptional parameter characteristics including extreme temperature resistance (-70°C to 260°C) and superior abrasion resistance, fundamentally improving the tubing's ability to withstand harsh environmental conditions compared to conventional materials
Solution Approach 2:
The patent employs a sacrificial grounding braid that can be easily replaced, providing a cost-effective solution for maintaining electrical grounding integrity throughout the wiring harness lifecycle, particularly in areas subject to wear
3Reliability
If a grounding braid is added to the wiring harness, then electrical grounding is improved, but the complexity of the assembly increases
Solution Approach 1:
The patent integrates the grounding braid with the existing wiring harness assembly, combining multiple functions (electrical grounding, mechanical support, and abrasion protection) into a single integrated component rather than adding separate elements
Solution Approach 2:
The grounding braid serves multiple functions simultaneously: providing electrical grounding path, acting as a mechanical support element, and offering additional abrasion protection to the wiring harness, thereby reducing the need for separate components
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 system offers reduced electrical conductivity, enhanced protection from abrasion and temperature fluctuations, ensuring reliable operation of high voltage wiring harnesses in vehicles under extreme conditions.
Implementation Method 1
The material used to form the tubing may include polytetrafluoroethylene to protect the high voltage wiring harness assembly from abrasion and to insulate the high voltage wiring harness assembly from substantial temperature fluctuations
Implementation Method 2
The coupling assembly may provide a water tight seal between the tubing and the adapter plate
Implementation Method 3
an adapter plate configured to provide a mechanical and electrical grounding connection to the vehicle
Data Source
AI summary
A system and method for connecting a high voltage wiring harness assembly to a vehicle. The system includes a tubing configured to provide an enclosure for the high voltage wiring harness assembly. The material used to form the tubing includes polytetrafluoroethylene to protect the high voltage wiring harness assembly from abrasion and to insulate the high voltage wiring harness assembly from substantial temperature fluctuations. The system may include an adapter plate configured to provide a mechanical and electrical grounding connection to the vehicle. The system may include a coupling assembly configured to couple the tubing and the adapter plate. The coupling provides a water tight seal between the tubing and the adapter plate. The high voltage wiring harness assembly includes a grounding braid. The coupling assembly is further configured to couple the grounding braid to the adapter plate for completing an electrical circuit between the grounding braid and the vehicle.