Split-Tube Wire Harness Shielding for Bend-Induced Tear Prevention
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Solution Overview
Problem
Metal foils used for electromagnetic shielding in wire harnesses are less flexible and prone to tearing when bent, leading to a decrease in the electromagnetic shielding function.
Innovation Solution
A wire harness design featuring a core wire with an insulating coating and an electromagnetic shield formed by combining split tubes with overlapping openings, allowing for deformation and maintaining shielding effectiveness during bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a metal foil is used as the electromagnetic shielding member, then the weight of the electromagnetic shielding member can be reduced, but the metal foil is less flexible and extensible, causing it to tear when the wire is bent sharply
Solution Approach 1:
The electromagnetic shielding member is divided into multiple segmented structures (such as multiple thin-walled tubes or a mesh structure) rather than using a single continuous metal foil. This segmentation allows each individual segment to deform independently when the wire is bent, preventing the entire shielding member from tearing while maintaining electromagnetic shielding effectiveness through the collective arrangement of segments.
2Weight of moving object
If a metal foil is used as the electromagnetic shielding member, then the weight can be reduced, but the electromagnetic shielding function decreases when the foil tears during bending
Solution Approach 1:
The electromagnetic shielding member is divided into multiple segmented structures (such as multiple thin-walled tubes or a mesh structure) rather than using a single continuous metal foil. This segmentation allows each individual segment to deform independently when the wire is bent, preventing the entire shielding member from tearing while maintaining electromagnetic shielding effectiveness through the collective arrangement of segments.
Solution Approach 2:
The patent employs thin-walled tube structures or mesh structures that possess inherent flexibility and extensibility. These flexible shell structures can accommodate sharp bends of the wire without tearing, thereby maintaining the integrity and reliability of the electromagnetic shielding function while keeping the weight low.
3Strength
If a braided wire is used as the electromagnetic shielding member, then the flexibility and extensibility are improved, but the weight increases compared to using a metal foil
Solution Approach 1:
The patent employs thin-walled tube structures or mesh structures that possess inherent flexibility and extensibility. These flexible shell structures can accommodate sharp bends of the wire without tearing, thereby maintaining the integrity and reliability of the electromagnetic shielding function while keeping the weight low.
Data Source
AI summary
A wire harness including: a wire having a core wire and an insulating coating that coats an outer periphery of the core wire; and an electromagnetic shield that surrounds an outer periphery of the wire, wherein: the electromagnetic shield has a plurality of split tubes that each have an opening in a horizontal cross-sectional shape thereof, the plurality of split tubes of the electromagnetic shield are combined such that the openings of the plurality of split tubes are fitted to each other, thereby forming a tubular body, a horizontal cross-sectional shape of the tubular body formed by combining the plurality of split tubes is a shape that corresponds to an outer peripheral surface of the core wire, and the plurality of split tubes of the electromagnetic shield are each in direct surface contact with the wire, or indirect surface contact with the wire via another layer.