Electromagnetic Shield Pipe Crimp Layout for Stable Wire Harness Bonding
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Solution Overview
Problem
The existing electromagnetic shield structures face issues with reduced holding strength and stability due to thickness variations at the connection portion between braided wires and electromagnetic shield pipes, particularly under heat cycles, repetitive bending, or tensile forces, leading to potential disconnection and instability in the energized state.
Innovation Solution
The electromagnetic shield structure addresses this by crimping braided wires without overlapping them, ensuring equal thickness and secure contact with the crimp member across the electromagnetic shield pipe's circumference, maintaining the holding strength and stability of the energized state by preventing gaps and ensuring uniform pressure from the crimp member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If braided wires are overlapped and crimped at the connection portion, then the shielding coverage is improved, but the holding strength is reduced due to thickness variations
Solution Approach 1:
The patent applies different arrangements of braided wires at different locations: at the connection portion (crimping location), the braided wires are arranged adjacently without overlap to ensure uniform thickness and holding strength, while at other portions, the braided wires may overlap to provide continuous shielding coverage. This local differentiation resolves the contradiction between shielding coverage and holding strength.
2Stability of the object's composition
If braided wires are overlapped at the connection portion, then the shielding continuity is improved, but the crimping stability deteriorates under heat cycles and tensile forces
Solution Approach 1:
The patent implements a localized arrangement where braided wires are positioned adjacently (without overlap) specifically at the connection portion to ensure uniform crimping and stability under environmental stresses, while maintaining shielding continuity through proper overlap in non-crimped regions. This resolves the contradiction between shielding continuity and crimping stability.
3Strength
If braided wires are arranged with uniform thickness at the connection portion, then the holding strength is maintained, but the shielding coverage may be reduced
Solution Approach 1:
The patent segments the braided wire arrangement into two functional zones: a connection portion where wires are adjacently arranged for uniform thickness and holding strength, and a non-connection portion where wires can overlap for continuous shielding. This segmentation allows each zone to optimize for its specific function without compromising the other.
Solution Approach 2:
Different spatial arrangements of braided wires are applied to different locations along the cable: adjacent arrangement at the connection portion for mechanical strength, and overlapping arrangement in other portions for shielding continuity. This local quality differentiation resolves the contradiction between holding strength and 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
This solution secures a stable energized state and maintains long-term holding strength by eliminating thickness variations and ensuring consistent contact between the braided wires and the electromagnetic shield pipe, enhancing the structural integrity and reliability of the shield structure.
Implementation Method 1
crimping braided wires without overlapping them, ensuring equal thickness and secure contact with the crimp member
Implementation Method 2
noise from the high-voltage electric wire is shielded so as not to be transmitted to the low-voltage electric wire in the interior of the electromagnetic shield pipe
Data Source
Figure 1a~1b
Figure 2a~3a
Figure 3b~4
AI summary
A braided wire 11a (a sheet-like portion 15a) and a braided wire 11b (the sheet-like portion 15b) that are two cylindrical flexible shield members are fixed with a crimp member 13 at different positions in the circumferential direction on a cross section perpendicular to the longitudinal direction of the electromagnetic shield pipe 3. Thus, the cylindrical end portions of the braided wires 11a and 11b are loosened, and each of sheet-like portions 15a and 15b is formed on the end portion, and the sheet-like portions 15a and 15b of the end portions of the braided wires 11a and 11b are disposed at different positions in the circumferential direction of the electromagnetic shield pipe 3 and fixed with the crimp member 13 on a metal layer 7 of the electromagnetic shield pipe 3. That is, the braided wires 11a and 11b are fixed in a section crimped by the crimp member 13 without being overlapped with each other in the circumferential direction of the electromagnetic shield pipe 3.