Shielded Wire Harness Connector Using Conductive Elastic Contact
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Solution Overview
Problem
Conventional wire harnesses with braided shields face issues during electrical connection due to loose or broken metal bare wires, making the adoption of electromagnetic shielding structures troublesome, especially at connector portions.
Innovation Solution
A wire harness design featuring a connector with a conductive resin or metal body, a conductive elastic member, and a heat-shrinkable shielding tube that electrically connects the connector, shielding member, and wire, providing a secure and easy-to-implement electromagnetic shielding structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a braided shield made of thin metal bare wires is used for electromagnetic shielding, then electromagnetic wave suppression is achieved, but the metal bare wires may come loose or break during electrical connection and stripping operations
Solution Approach 1:
The patent changes the material parameter of the shielding structure from traditional braided metal wires to a conductive elastic member made of conductive rubber or similar material. This material substitution eliminates the loosening and breaking issues while maintaining electromagnetic shielding effectiveness through the conductive properties of the elastic material.
Solution Approach 2:
The patent employs a composite structure combining conductive elastic material with insulating housing and heat-shrinkable tube. The conductive elastic member provides both mechanical flexibility and electromagnetic shielding, while the heat-shrinkable tube adds protective encapsulation, creating a multi-functional composite shielding system.
2Stability of the object's composition
If a braided shield portion is electrically connected to a shielding member, then electromagnetic shielding continuity is achieved, but the operation becomes troublesome due to wire loosening and breaking
Solution Approach 1:
The patent extracts the conductive function from the mechanical wire structure and integrates it into the elastic member that is pre-formed as part of the connector assembly. This eliminates the need for separate wire stripping and connection operations, as the conductive elastic member itself serves as the electrical connection path.
Solution Approach 2:
The conductive elastic member is designed to automatically establish electrical connection through its elastic deformation and contact with mating components. The elastic nature allows self-adjustment and self-maintenance of electrical contact without requiring precise manual alignment or additional fastening operations.
3Reliability
If a heat-shrinkable shielding tube with conductive portion is used to cover the wire, then electromagnetic shielding is improved and connection reliability is enhanced, but the manufacturing process becomes more complex
Solution Approach 1:
The heat-shrinkable shielding tube is pre-applied to the wire assembly before final connector assembly. This preliminary positioning ensures proper alignment and electrical contact configuration is established in advance, simplifying the final assembly process rather than complicating it, as the tube acts as a pre-configured shielding and alignment guide.
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 enables easy adoption of electromagnetic shielding, prevents loose connections, and improves sealing and heat dissipation while avoiding issues like wire breakage and noise leakage, enhancing the reliability and performance of the wire harness.
Implementation Method 1
a heat-shrinkable shielding tube having a conductive portion that is configured to surround the circumference of the wire
Data Source
AI summary
A wire harness including a wire and a connector, wherein the connector includes a connector main body that is partially or entirely made of a conductive resin or is partially formed by a conductive portion, a shield that is made of a conductive metal and covers a periphery of the connector main body, and a conductive elastic member that is provided between the connector main body and the shield, a circumference of the wire is covered by a tube, the tube including a heat-shrinkable shielding tube having a conductive portion that is configured to surround the circumference of the wire, and in a state in which the tube is attached to an attachment of the connector main body, the conductive portion of the tube, the connector main body, the conductive elastic member, and the shield are electrically connected to each other.