Shielded Wire Harness with Conductive Sheet and Protection Tape
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Solution Overview
Problem
Conventional methods for manufacturing shielded wire harnesses are cumbersome, requiring complex apparatuses and increased man-hours due to the need for individual fabrication of shielded wire harnesses matching specific shield circuits, and pose difficulties in automating terminal end treatments.
Innovation Solution
A shielded wire harness is manufactured by wrapping a conductive sheet with a resin layer over electric wires, using a flexible protection tape to secure the sheet, allowing for easy fabrication and automation, with the conductive sheet being cut to match desired lengths and terminal ends exposed for connection, simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual shielded wire harnesses are fabricated to match specific shield circuits, then electromagnetic shielding performance is ensured, but manufacturing complexity and processing time increase significantly
Solution Approach 1:
The patent applies universality by creating a standardized shielded wire harness structure that can be used across multiple shield circuits. The common bundle design allows a single harness configuration to serve multiple circuits, eliminating the need for individual customization while maintaining shielding effectiveness through the standardized conductive sheet and resin layer construction.
Solution Approach 2:
The patent merges multiple individual wire harnesses into a single common bundle. By combining multiple circuits into one unified shielded structure with a shared conductive sheet and resin layer, the manufacturing process is simplified while maintaining the electromagnetic shielding performance required for each individual circuit.
2Manufacturing precision
If conventional individual fabrication methods are used, then shield circuit matching is achieved, but automation of terminal end treatments becomes difficult
Solution Approach 1:
The standardized common bundle design enables automation by providing a uniform structure for terminal end treatments. All wires within the common bundle follow the same configuration and shielding structure, allowing automated equipment to process terminal ends consistently across multiple circuits without requiring complex individual adjustments for each circuit match.
3Manufacturing precision
If complex manufacturing apparatuses are used for individual fabrication, then precise shield circuit matching is achieved, but processing costs increase
Solution Approach 1:
The patent reduces processing costs by merging multiple individual fabrication processes into a single common bundle manufacturing process. The standardized structure allows for more efficient production using simpler, less expensive equipment while maintaining the required shield circuit matching through uniform design specifications.
Solution Approach 2:
The universal common bundle design enables a single manufacturing process to produce harnesses suitable for multiple shield circuits, eliminating the need for expensive custom fabrication equipment and reducing overall processing costs while maintaining precise circuit matching through standardized dimensions and configurations.
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 method simplifies the manufacturing process, reduces processing costs, and enhances electromagnetic shielding performance while allowing for easier management and automation of terminal end treatments.
Implementation Method 1
A shielded wire harness is used owing to a necessity to perform an electromagnetic shield for protection from an electromagnetic noise
Implementation Method 2
The conductive sheet 5 has structure in which a resin layer made of insulating resin is stacked on metal foil
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A shielded wire harness (1) includes: a wire harness (3); a conductive sheet (5) to be wrapped around the wire harness (3) in a parallel state to the wire harness (3), the conductive sheet having a long belt shape along a longitudinal direction of the wire harness (3); and a long protection tape (7) to be spirally wound around an outer circumference of the conductive sheet (5) wrapped around the wire harness (3).