Vacuum-Contact Wire Harness for Lower Thermal Resistance
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Solution Overview
Problem
Existing wire harnesses with metal exterior members suffer from high thermal resistance due to trapped heat caused by low thermal conductivity of air and sealed interiors, leading to inefficient heat dissipation.
Innovation Solution
A flexible tubular exterior member is brought into close contact with electric wires by adjusting internal pressure to be lower than atmospheric pressure, using a check valve to allow air outflow and maintain airtightness, minimizing thermal resistance through reduced air interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal pipe is used as the exterior member to provide structural strength, then the mechanical strength is improved, but the thermal resistance increases due to air trapping between the wires and the pipe surface
Solution Approach 1:
The patent changes the physical state of the air between the electric wires and exterior member by creating a vacuum environment. This removes the air medium that causes thermal resistance, allowing direct thermal contact between the wires and the exterior member surface, thereby resolving the contradiction between structural strength and heat dissipation.
Solution Approach 2:
The patent creates a vacuum environment (inert atmosphere without gas molecules) within the exterior member to eliminate air interference. This vacuum environment removes the thermal insulation effect of air while maintaining the structural integrity of the metal pipe exterior member.
2Reliability
If the interior of the exterior member is sealed in a liquid-tight manner for waterproofing, then the waterproof performance is improved, but heat dissipation deteriorates because hot air cannot escape to the atmosphere
Solution Approach 1:
The patent changes the physical state from atmospheric pressure with air to vacuum conditions. This eliminates the air that would trap heat while maintaining the liquid-tight seal, allowing the sealed environment to become thermally conductive rather than insulating.
Solution Approach 2:
The patent converts the harmful effect of trapped air (thermal insulation) into a benefit by removing the air entirely through vacuum creation. The sealed environment that originally trapped hot air now becomes an efficient heat transfer path when the air is removed, turning the waterproof seal from a heat-trapping feature into a heat-dissipating structure.
3Reliability
If air exists between the electric wires and the inner surface of the exterior member, then the wires are electrically isolated, but the thermal resistance becomes high due to air's low thermal conductivity
Solution Approach 1:
The patent changes the medium between the wires and exterior member from air to vacuum. This eliminates the thermal resistance of air while the exterior member itself maintains the electrical isolation function, separating the thermal and electrical functions.
Solution Approach 2:
The patent separates the thermal management function from the electrical isolation function. The vacuum environment handles thermal conduction while the exterior member structure maintains electrical isolation, allowing each function to be optimized independently without contradiction.
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
Enhances heat transfer efficiency by minimizing air interference, resulting in improved heat dissipation from electric wires to the exterior member.
Implementation Method 1
adjusting an internal pressure of the exterior tube to be lower than atmospheric pressure
Implementation Method 2
the heat generated by the electric wires is transferred to the exterior member and released into the atmosphere from the outer circumferential surface of the exterior member
Implementation Method 3
released into the atmosphere from the outer circumferential surface of the exterior member
Implementation Method 4
a check valve that allows air in the exterior member to flow out to an atmosphere, and restricts air from flowing into an interior of the exterior member
Data Source
AI summary
A wire harness that includes: an exterior tube that is flexible and tubular; and electric wires inserted into the exterior tube, wherein the exterior tube is brought close to or into close contact with the electric wires by adjusting an internal pressure of the exterior tube to be lower than atmospheric pressure.