Wire Harness Braid With Resin Element Wires for Abrasion Resistance
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Solution Overview
Problem
Conventional wire harness braids lack sufficient abrasion and impact resistance, necessitating an additional outer covering member that increases component count, weight, and cost, while compromising electromagnetic shielding functionality.
Innovation Solution
A braid composed of element wire bundles with a metal core wire, surrounded by resin element wires for abrasion and impact resistance, and drain metal element wires for electrical conductivity, which contact each other to maintain electromagnetic shielding and serve as an outer covering member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a braid is used for electromagnetic shielding, then electromagnetic shielding function is provided, but abrasion resistance and impact resistance are insufficient
Solution Approach 1:
The braid uses composite element wire bundles combining metal element wires (for electromagnetic shielding) with resin element wires (for abrasion and impact resistance). This composite structure allows the metal wires to provide shielding while the resin wires provide mechanical protection, resolving the contradiction between electromagnetic shielding function and mechanical strength.
2Strength
If an outer covering member is provided outside the braid, then abrasion resistance and impact resistance are improved, but the number of components, weight, and cost increase
Solution Approach 1:
The invention merges the functions of the braid and the outer covering member into a single integrated structure. The resin element wires within the braid itself provide the protective function that would otherwise require a separate outer covering member, thereby reducing component count while maintaining abrasion and impact resistance.
Solution Approach 2:
The element wire bundles serve multiple functions simultaneously: metal element wires provide electromagnetic shielding, resin element wires provide mechanical protection (abrasion and impact resistance), and the combined structure eliminates the need for separate protective covering members, achieving multi-functionality within a single component.
3Strength
If resin element wires surround metal element wires, then abrasion and impact resistance are improved, but electrical conductivity may be affected
Solution Approach 1:
The resin element wires are strategically positioned to surround and protect metal element wires at specific locations where abrasion and impact are most likely to occur, while maintaining the overall electrical conductivity of the braid structure. This localized protection approach ensures mechanical strength is improved without compromising the electromagnetic shielding function.
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
The braid achieves both electromagnetic shielding and outer covering functions with improved abrasion and impact resistance, reducing the need for additional components, weight, and cost, while maintaining electromagnetic shielding integrity.
Implementation Method 1
The braid is provided to exert an electromagnetic shielding function for the plurality of electric wires
Implementation Method 2
a drain metal element wire that has electrical conductivity and that is disposed with the resin element wires and contacts with the metal element wire; and wherein the drain metal element wires in the plurality of element wire bundles contact to each other
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3
AI summary
A braid (40) for a wire harness includes a plurality of element wire bundles (43), each of which is formed of a plurality of element wires, and the plurality of element wire bundles being braided Into a tubular shape. Each of the plurality of element wire bundles includes a metal element wire (44) that has electrical conductivity, a plurality of resin element wires (45) that have abrasion resistance and that are disposed to surround the metal element wire, and a drain metal element wire (46) that has electrical conductivity and that is disposed with the resin element wires and contacts with the metal element wire. The drain metal element wires in the plurality of element wire bundles contact to each other.