Resin-Infused Braided Shield for Rigid Pliable Wire Harness
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electrical harnesses in vehicles, particularly in aerospace, face weight and efficiency issues due to the need for frequent supportive brackets and clamps, which also restrict the harness path and add weight, while existing insulation and protection methods further increase weight without addressing sagging and chafing effectively.
Innovation Solution
An electrical harness with a curable resin-infused braided shield that provides rigidity in some sections and flexibility in others, allowing for reduced support intervals and improved path efficiency, using a combination of metal clad fibers and resin infusion to protect against electromagnetic interference and mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple brackets and clamps are used to support the wire harness at close intervals, then the harness is protected from sagging and contact with surfaces, but the weight of the harness system increases and the path of the harness is restricted
Solution Approach 1:
The wire harness is divided into multiple rigid sections separated by flexible joints. Each rigid section can support itself without requiring frequent external brackets, while the flexible joints allow the harness to adapt to different paths and mounting configurations. This segmentation reduces the number of support points needed while maintaining structural integrity.
Solution Approach 2:
The wire harness incorporates composite construction with rigid sections made from materials providing structural support and flexible sections made from pliable materials. This composite approach allows the harness to maintain its shape and support itself over longer intervals without additional brackets, reducing overall system weight while preserving protective functions.
2Reliability
If brackets and clamps are installed at regular short intervals, then the harness is supported adequately, but the harness path must follow mounting structures which may not be the most efficient or direct path
Solution Approach 1:
The wire harness incorporates flexible joints between rigid sections, allowing the harness to dynamically adapt its path between mounting points. This flexibility enables the harness to follow more direct and efficient routes without requiring support at every structural feature, reducing overall path length while maintaining adequate support.
Solution Approach 2:
The harness design changes the structural parameters along its length, with rigid sections providing support over longer intervals and flexible sections allowing path adaptation. This parameter variation enables the harness to achieve both adequate support and efficient routing without being constrained to follow every mounting structure.
3Object-affected harmful factors
If multiple layers of thermal and electromagnetic insulation and overbraid protection are added, then the harness is protected from chafing, high temperatures, and electromagnetic interference, but the weight of the harness system increases
Solution Approach 1:
The wire harness uses composite material construction where the rigid sections provide structural protection against chafing and mechanical stress, reducing or eliminating the need for separate overbraid protection layers. The flexible sections provide natural flexibility and protection, allowing the harness to maintain protection against harmful factors while reducing overall weight through material optimization.
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 reduces weight and enhances the structural integrity of the harness by providing necessary support while maintaining flexibility, thus improving efficiency and reducing fuel burn, while also offering effective protection against electromagnetic interference and mechanical stress.
Implementation Method 1
at least a first portion of the braided shield comprises a first cured resin imparting rigidity to the first portion of the braided shield
Data Source
AI summary
Electrical harnesses and methods of manufacturing electrical harnesses are disclosed. Electrical harnesses may comprise an electrically conductive wire, and a resin infused braided shield surrounding a portion of the electrically conductive wire, wherein at least a portion of the braided shield is infused with a curable resin. Electrical harnesses may comprise an electrically conductive wire, and a braided shield surrounding a portion of the electrically conductive wire, wherein at least a first portion of the braided shield comprises a first cured resin imparting rigidity to the first portion of the braided shield and at least a second portion of the braided shield that is pliable.