Shielded Wire Routing Structure for Bending Stress and Heat Dissipation
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Solution Overview
Problem
Shielded electric wires face challenges in maintaining heat dissipation and shielding performance when bent, as existing designs often compromise on these aspects due to stress and structural limitations.
Innovation Solution
A routing structure for shielded electric wires featuring a resin tube with a shield layer interposed between inner and outer resins, where the tensile strength of the resins exceeds bending stress, and the shield layer has a resistance of 103.8 mΩ/m or less and a density of 50% or more, ensuring effective shielding and heat dissipation across various frequencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the shielded electric wire is bent to achieve routing flexibility, then the ease of operation is improved, but the heat dissipation performance deteriorates due to crack formation and air layer generation
Solution Approach 1:
The patent employs a composite resin tube structure consisting of an inner resin layer, a shield layer, and an outer resin layer. This composite structure allows the outer resin to flex during bending while the inner resin maintains structural integrity, preventing cracks that would compromise heat dissipation. The shield layer embedded within provides both electromagnetic shielding and thermal conduction pathways, ensuring heat dissipation performance is maintained even when the wire is bent to achieve routing flexibility.
2Object-affected harmful factors
If the shield layer density is increased to improve shielding performance, then the shielding effect is improved, but the heat dissipation performance deteriorates due to reduced thermal conduction pathways
Solution Approach 1:
The patent applies local quality by differentiating the functional properties of different layers. The shield layer is positioned locally between the inner and outer resin layers, providing concentrated electromagnetic shielding where needed. The outer resin layer is formulated with specific thermal conductivity properties to compensate for the thermal resistance introduced by the dense shield layer, creating localized thermal management zones that maintain overall heat dissipation performance while achieving superior shielding.
3Ease of manufacture
If the resin tube structure is simplified to reduce manufacturing complexity, then the ease of manufacture is improved, but the reliability deteriorates due to insufficient protection against bending stress and air layer formation
Solution Approach 1:
The patent segments the resin tube into distinct functional layers: an inner resin layer for structural support, a shield layer for electromagnetic protection, and an outer resin layer for flexibility and environmental protection. This segmentation allows each layer to be optimized for its specific function while maintaining overall structural integrity during bending. The layered structure prevents air layer formation between the shield and resin, ensuring reliable adhesion and consistent performance without requiring complex manufacturing processes.
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 secures both shielding and heat dissipation performance by preventing cracks and air layer formation during bending, maintaining a shielding effect of 30 dB across 10 kHz to 1 GHz and ensuring heat dissipation efficiency.
Implementation Method 1
the shield layer has a shield resistance equal to or smaller than 103.8 mΩ/m and a shield density equal to or greater than 50%... the shielding performance is 30 dB or more
Implementation Method 2
a tensile strength of the inner-side resin and the outer-side resin is greater than a bending stress to be generated when the shielded electric wire is bent... securing heat dissipation performance
Data Source
AI summary
A routing structure of a shielded electric wire, the shielded electric wire including an electric wire and a resin tube is routed in a state of being bent, the resin tube including a shield layer, an inner-side resin and an outer-side resin, the shield layer being interposed between the inner-side resin and the outer-side resin, is provided. A tensile strength of the inner-side resin and the outer-side resin is greater than a bending stress to be generated when the shielded electric wire is bent with a minimum bend radius in the routing structure. The shield layer has a shield resistance equal to or smaller than 103.8 mΩ/m and a shield density equal to or greater than 50%, the shield density being a ratio of an area of a surface of the electric wire covered by the shield layer to an area of the surface of the electric wire.