Segmented Electromagnetic Shielding Bracket for Wire Harness
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Solution Overview
Problem
Conventional tube-shaped braided wires for electromagnetic shielding require pre-insertion of electrical wires, limiting manufacturing flexibility and increasing the size, weight, and cost of wire harnesses, and pose challenges in positioning the braided wire over shield frame portions, especially when space is limited.
Innovation Solution
An electromagnetic shielding tool comprising a metallic cloth with conductive thread fabric and bracket sets that form a ring shape around the electrical wire, allowing post-provision of the shielding member without increasing the size or weight of the wire harness, and enabling direct fixation to the shield frame portions without intermediate components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a tube-shaped braided wire is used for electromagnetic shielding, then the shielding member can change shape in accordance with the electrical wire, but the electrical wire must be pre-inserted into the braided wire before connector attachment, limiting manufacturing flexibility
Solution Approach 1:
The braided wire is divided into multiple separate strands rather than being a continuous tube. These individual strands can be independently manipulated and attached to the electrical wire after connector installation, eliminating the need for pre-insertion while maintaining shape adaptability through the flexible nature of the separate strands.
Solution Approach 2:
Instead of inserting the electrical wire into the braided wire tube (traditional approach), the invention attaches the braided wire strands to the external surface of the electrical wire. This inverted approach allows connector attachment first, then shielding application, reversing the traditional sequence to gain manufacturing flexibility.
2Ease of operation
If post-provision of the braided wire is enabled, then manufacturing freedom increases, but a larger braided wire must be used to accommodate connector dimensions, increasing layout space, weight, and cost
Solution Approach 1:
By segmenting the braided wire into separate strands, the shielding coverage is achieved using only the necessary amount of material directly around the electrical wire, rather than requiring a large-diameter tube that could accommodate connectors. This reduces the total material used, decreasing weight and layout space while maintaining post-provision capability.
Solution Approach 2:
The braided wire strands are applied locally around the electrical wire where shielding is needed, rather than using a uniformly large tube. This localized application ensures minimal material usage while providing effective electromagnetic shielding, reducing overall weight and cost without compromising manufacturing flexibility.
3Reliability
If the two ends of the braided wire are placed over shield frame portions of two closely arranged casings, then shielding coverage is achieved, but there is little leeway in positioning the braided wire in the axial direction, making attachment difficult
Solution Approach 1:
The braided wire is segmented into multiple independent strands that can be individually positioned and attached along the electrical wire. This segmentation provides flexibility in axial positioning, allowing the strands to be distributed between shield frame portions of closely arranged casings without requiring precise positioning of a continuous tube, thereby facilitating easier attachment while maintaining shielding coverage.
Solution Approach 2:
The braided wire strands are made dynamically adjustable in their axial positions rather than being fixed in a continuous tube structure. This dynamic positioning capability allows the strands to be flexibly arranged to accommodate varying distances between shield frame portions, making attachment easier in confined spaces while ensuring reliable shielding coverage.
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 stable electromagnetic shielding with reduced parts management and handling time, prevents detachment from the shield frame portions, and allows for easier attachment in confined spaces, while maintaining effective noise blocking performance.
Implementation Method 1
an electromagnetic shielding tool for blocking electromagnetic noise in a wire harness installed in a vehicle
Data Source
AI summary
An electromagnetic shielding tool that includes a metallic cloth and two bracket body portions. The two bracket body portions each include two elongated portions and a coupling portion, and respectively hold a first outer edge portion and a second outer edge portion on the side opposite to the first outer edge portion among four outer edge portions of the metallic cloth so as to form a ring that surrounds the periphery of electrical wires. The two elongated portions are made of a conductive material, are joined to the metallic cloth in the state of being arranged in series along an outer edge portion of the metallic cloth, and form a ring shape due to being combined with each other on two sides of the electrical wires. The coupling portion couples end portions of the two elongated portions to each other and holds the two elongated portions in the ring shape.