Underfloor Shielded Harness Conductive Plate Design
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Solution Overview
Problem
Existing underfloor wire harnesses for electric vehicles face challenges in manufacturing complexity, component count, and water-induced corrosion, particularly due to insufficient shielding and drainage in harsh underfloor environments.
Innovation Solution
A shielded harness design featuring a wound conductive plate with multiple internal spaces, where high-voltage and low-voltage cables are bundled and shielded within these spaces, allowing for reduced manufacturing steps and components, and enabling water drainage to prevent corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If each high-voltage cable is covered with a conductive braid and bundled with a sheath member, then shield performance is improved, but the number of manufacturing steps and components increases
Solution Approach 1:
The patent combines multiple shielding functions into a single conductive plate structure that simultaneously shields both high-voltage and low-voltage cables. The conductive plate integrates the shielding function that would otherwise require separate conductive braids for each cable, reducing component count while maintaining shield performance.
Solution Approach 2:
The conductive plate serves multiple functions: it acts as a shield for high-voltage cables, provides structural support for the entire harness assembly, and creates separation between high-voltage and low-voltage circuits. This multi-functionality eliminates the need for separate sheath members and reduces manufacturing steps.
2Ease of manufacture
If an insulating sheet is curled to bundle cables, then manufacturing steps are reduced, but the sheet is insufficient for exterior member functions and water can penetrate causing corrosion
Solution Approach 1:
The patent changes the material parameter from a non-conductive insulating sheet to a conductive plate, which provides both the mechanical strength needed for exterior member functions and the electrical conductivity needed for shielding. This parameter change enables the structure to simultaneously provide mechanical protection and electromagnetic shielding without requiring additional components.
3Reliability
If a metal pipe with shield wall is used, then exterior member functions are satisfied, but the number of components increases and water can still penetrate causing corrosion
Solution Approach 1:
The conductive plate merges the shielding function with the structural support function into a single component. Unlike the metal pipe with shield wall that requires separate components, the conductive plate simultaneously provides both shielding and structural integrity, reducing the number of components while satisfying exterior member requirements.
4Ease of manufacture
If water enters the insulating sheet or metal pipe, then water stays inside until draining, but this causes corrosion of various members
Solution Approach 1:
The conductive plate incorporates a porous structure with through-holes that allow water to drain outward rather than accumulate inside. This porous design maintains the simple structure advantage while eliminating the corrosion risk associated with water retention in closed structures.
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 design reduces manufacturing complexity and component count while enhancing shielding and preventing water-induced corrosion, ensuring the harness meets functional requirements for the underfloor environment.
Implementation Method 1
a long conductive plate 103 which is wound so as to have at least two internal spaces in a cross section taken perpendicularly to the longitudinal direction; a high-voltage cable 102 which is inserted in one of the at least two internal spaces 104, 105 of the conductive plate 103; and a low-voltage cable 101 which is inserted in an internal space other than the one in which the high-voltage cable is inserted, of the at least two internal spaces
Data Source
AI summary
An underfloor shielded harness (100) has a long conductive plate which is wound so as to have at least two internal spaces (104, 105) in a cross section taken perpendicularly to the longitudinal direction. High-voltage cables (102) is inserted in the internal space (104) of the conductive plate (103) and the low-voltage cable (101) is inserted in the internal space (105) that is different from the internal space (104) in which the high-voltage cables (102) is inserted. At least one of the two internal spaces (104, 105) communicates with the outside of the spaces (104, 105) formed by the conductive plate (103).