Shield Conductive Path Reducing Manufacturing Processes

Solution Overview

Problem

The existing shield conductive paths in vehicles require a larger diameter shield pipe to accommodate stranded electrical lines, which increases manufacturing processes due to the need for single-core line manufacturing and sheathing stripping, and there is a desire to reduce these processes while maintaining electromagnetic shielding and protection.

Innovation Solution

A shield conductive path configuration using a single-core conductor inserted into a shield pipe with a stranded line conductor connected to its end, where the stranded line is enveloped in sheathing and both conductors are protected by a tubular member, such as a shrink tube, eliminating the need for single-core line manufacturing and sheathing stripping processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If stranded electrical lines are used to connect devices, then the electrical lines can flex easily to match junction positions, but the diameter dimension of the shield pipe must be made larger to accommodate them

Engineering Contradiction:

Improveflexibility of electrical lineVSAvoiddiameter dimension of shield pipe

Core Design Contradiction:

Ease of operationVSVolume of moving object

Solution Approach 1:

The electrical line is divided into two distinct segments: a single-core conductor segment for insertion into the shield pipe, and a stranded line conductor segment for connection to devices. Each segment is optimized for its specific function, with the single-core portion providing flexibility within the shield and the stranded portion providing flexibility at the connection point.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the electrical line are given different structural qualities - the single-core conductor has a specific construction suitable for shielded environments, while the stranded line conductor has a different construction suitable for connection work. This local differentiation allows each part to optimize its performance for its specific role.

Inventive Principle:

Principle #3Local quality

2Volume of moving object

If single-core electrical line is used to reduce diameter dimension, then the electrical line can be inserted into small diameter shield pipe, but the end portion cannot be freely bent to match junction positions

Engineering Contradiction:

Improvediameter dimension of shield pipeVSAvoidflexibility at junction portion

Core Design Contradiction:

Volume of moving objectVSEase of operation

Solution Approach 1:

The electrical line is divided into two distinct segments: a single-core conductor segment for insertion into the shield pipe, and a stranded line conductor segment for connection to devices. Each segment is optimized for its specific function, with the single-core portion providing flexibility within the shield and the stranded portion providing flexibility at the connection point.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the electrical line are given different structural qualities - the single-core conductor has a specific construction suitable for shielded environments, while the stranded line conductor has a different construction suitable for connection work. This local differentiation allows each part to optimize its performance for its specific role.

Inventive Principle:

Principle #3Local quality

3Reliability

If both single-core and stranded line conductors are used with separate sheathing processes, then the electrical line can have optimal properties in both sections, but the number of manufacturing processes increases

Engineering Contradiction:

Improveperformance of electrical lineVSAvoidnumber of manufacturing processes

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The sheathing processes for both the single-core conductor and stranded line conductor are merged into a single integrated process. The sheathing is applied simultaneously to both conductors, and the protective coating is applied to both sections in one operation, reducing the total number of manufacturing steps while maintaining the distinct structural properties of each conductor type.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS9676349B2Shield conductive path

Publication Date: 2017.06.13 SUMITOMO WIRING SYSTEMS LTD

AI summary

A shield conductive path with which the number of manufacturing processes can be reduced is provided. The shield conductive path includes: a single-core conductor made up of a single conductor inserted into a pipe with a shield function, a stranded line conductor made up of a plurality of twisted individual wires connected to an end portion of the single core conductor, a sheathing that envelops the stranded line conductor in a state in which a junction portion of the stranded line conductor that is joined to the single-core conductor is exposed, and a shrink tube that envelops, protects and insulates the entirety of the single-core conductor and a portion of the stranded line conductor that is exposed from the sheathing.