Shielding Wire Metal Foil Envelope Design
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Solution Overview
Problem
Conventional shield wires for high-tension applications in hybrid and electric vehicles are either too heavy due to braided wire construction or fail to provide adequate shielding due to metal foil and drain line configurations, leading to deformation and instability in the wire harness.
Innovation Solution
A shield wire design utilizing a metal foil shield member that envelops the inner wire part, with semicircular end arrangements to prevent collapse and ensure stable contact, eliminating the need for a drain line to achieve a lighter, more effective shielding solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a shield member formed with braided wire is used, then the shielding function is provided, but the shield wire becomes relatively heavy
Solution Approach 1:
The patent changes the material parameter from braided wire to metal foil, fundamentally altering the structural parameters of the shield member. This parameter change reduces the weight while maintaining the shielding function, as metal foil has lower density and mass compared to braided wire construction.
Solution Approach 2:
The patent employs a composite structure combining metal foil with resin coating, creating a composite material shield member. This composite approach provides both the lightweight advantage of metal foil and the protective benefits of resin encapsulation, achieving weight reduction while preserving shielding effectiveness.
2Reliability
If a shield member formed with metal foil and drain line is used, then the shielding function is provided, but the external form becomes deformed due to drain line thickness
Solution Approach 1:
The patent extracts and removes the drain line component from the shield member structure. By eliminating the drain line, the thick, deforming element is taken out of the system, allowing the metal foil shield member to maintain a smooth, uniform external form without the deformation caused by thick drain line positioning.
Solution Approach 2:
The patent uses a thin metal foil shield member that can be smoothly formed and coated with resin. The thin film structure of the metal foil allows for smooth external form without the thickness issues of drain lines, and the resin coating provides additional protection while maintaining the smooth exterior.
3Reliability
If the drain line is arranged between electric wires, then the shielding function is provided, but the drain line does not come into sufficient contact with the metal foil
Solution Approach 1:
The patent removes the drain line from the shield member structure entirely. This extraction eliminates the manufacturing precision problem of ensuring sufficient contact between the drain line and metal foil, as the drain line component no longer exists in the design. The metal foil itself serves as the complete shield member.
Solution Approach 2:
The metal foil shield member performs multiple functions simultaneously: it provides electromagnetic shielding, serves as the structural component, and eliminates the need for a separate drain line. This multi-functionality approach consolidates the shield member into a single component that achieves shielding without the contact issues of drain line arrangements.
4Reliability
If the end part of metal foil shield member collapses or bounds between electric wires, then the shielding function cannot be sufficiently exhibited, but the structure becomes complicated to prevent collapse
Solution Approach 1:
The patent applies preliminary action by coating the metal foil shield member with resin before the end parts can collapse or bound. This resin coating is applied in advance, creating a protective layer that maintains the structural integrity of the metal foil and prevents collapse or binding between electric wires during subsequent handling and installation.
Solution Approach 2:
The resin coating acts as a flexible protective shell around the metal foil shield member. This thin film structure provides mechanical support to prevent collapse and binding of the end parts, while maintaining flexibility and not significantly increasing the overall size or complexity of the shield member.
Data Source
Figure 1A~1C
Figure 2A~2B
Figure 3A~3C
AI summary
In a shield wire (21), a sheet shaped metal foil shield member (23) is provided so as to envelop an inner wire part (22) having a plurality of conductors (25) and insulators (26). In the shield wire (23), the inner wire part (22) is enveloped by the metal foil shield member (23) so that the inner wire part (22) is held and an end part of the metal foil shield member (23) is avoided from collapsing or the end is avoided from bounding.