Shielded Conductive Path with Partial Welding for Bend Strength
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Solution Overview
Problem
The existing shielded conductive paths in vehicles face poor workability due to frictional resistance between electrical wires and shielding pipes, leading to inefficiencies in manufacturing time and process.
Innovation Solution
A shielded conductive path is created by joining two semi-cylindrical metal members with a bend, using partial and full welds to house electrical wires, where the first weld covers the bend and has a wider radial joining range for maximum bonding strength, and the second weld covers the rest with a narrower radial range for reduced welding time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the shielding pipe is installed as a complete cylinder with electrical wires inserted, then the shielding function is effective, but the frictional resistance between electrical wire and inner circumferential surface results in poor workability
Solution Approach 1:
The shielding pipe is divided into two semi-cylindrical members that can be opened like a clamp, allowing electrical wires to be gripped without insertion. This segmentation maintains the shielding function when closed while dramatically improving workability during installation.
2Ease of operation
If the shielding pipe is divided into two semi-cylindrical members that are joined by welding, then electrical wire housing spaces are open and insertion operation is not required, but the welding process for long semi-cylindrical members takes time
Solution Approach 1:
Welding is applied selectively only at specific locations (both end surfaces and the bend portion) rather than along the entire length of the semi-cylindrical members. This local quality approach maintains structural integrity and sealing while dramatically reducing welding time.
3Reliability
If welding is applied to the entire length of semi-cylindrical members, then liquid-tight joining is achieved, but the manufacturing time increases
Solution Approach 1:
The welding is concentrated at critical locations (end surfaces and bend portion) where liquid-tight sealing is most needed, rather than applying welding uniformly along the entire length. This achieves adequate sealing reliability while improving productivity.
Solution Approach 2:
Instead of welding the entire surface, only partial regions are welded - specifically the end surfaces and bend portion - which provides sufficient liquid-tight joining for the application while reducing manufacturing time.
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 configuration prevents water ingress, maintains bonding strength, and significantly reduces manufacturing time by optimizing the welding process, ensuring efficient assembly of the shielded conductive path.
Implementation Method 1
a first weld that is provided only in a partial region of the shielding pipe that includes at least the bend in the axial direction, the first weld liquid-tightly joining the two semi-cylindrical members; and a second weld that is provided in all regions of the shielding pipe other than the first weld in the axial direction, the second weld liquid-tightly joining the two semi-cylindrical members
Data Source
AI summary
A shielded conductive path, including: a cylindrical shielding pipe that is in a state in which two semi-cylindrical members made of a metal material are joined together, and that is provided with a bend at a portion located in an axial direction; an electrical wire housed in the shielding pipe; a first weld that is provided only in a partial region of the shielding pipe that includes at least the bend in the axial direction, the first weld liquid-tightly joining the two semi-cylindrical members; and a second weld that is provided in all regions of the shielding pipe other than the first weld in the axial direction, the second weld liquid-tightly joining the two semi-cylindrical members, wherein a joining range of the second weld in a radial direction is narrower than a joining range of the first weld in the radial direction.