Vehicle Wire Harness Layout for Exhaust Heat Shielding
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Solution Overview
Problem
Wire harnesses routed alongside exhaust pipes in vehicles are susceptible to heat from the exhaust gases, requiring improved heat resistance and reduced heat transmission.
Innovation Solution
A wire harness configuration with a first wire member alongside the exhaust pipe and a second wire member on the opposite side, shielded by a metal tube, where the second wire member has a lower heat resistance insulation coating and is fixed to the first wire member and/or pipe, reducing direct heat transmission and fixing points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the wire harness is routed alongside the exhaust pipe to save space and improve layout efficiency, then the vehicle's space utilization is improved, but the wire harness is exposed to high heat from the exhaust pipe reducing its heat resistance performance
Solution Approach 1:
The wire harness is divided into two separate wire members (first wire member and second wire member) positioned on opposite sides of the exhaust pipe. This segmentation allows the first wire member to be closer to the exhaust pipe while the second wire member is shielded, thus maintaining compact layout while protecting against heat exposure.
Solution Approach 2:
The first wire member acts as an intermediary shield between the exhaust pipe and the second wire member. By positioning the first wire member alongside the exhaust pipe and the second wire member on the opposite side, the first wire member blocks direct heat transmission to the second wire member, protecting it from thermal damage.
2Object-affected harmful factors
If a metal tube is added to shield the second wire member from heat, then the heat resistance performance is improved, but the device complexity and cost increase
Solution Approach 1:
The first wire member serves multiple functions: it provides electrical connectivity and simultaneously acts as a thermal shield for the second wire member. This multi-functionality eliminates the need for additional metal tube shielding structures, reducing device complexity while maintaining heat resistance performance.
Solution Approach 2:
The wire harness structure uses its own components (the first wire member) to provide protection against heat for the second wire member. The system is self-shielding, eliminating the need for external protective structures and reducing overall complexity.
3Ease of manufacture
If the second wire member uses insulation coating with lower heat resistance to reduce cost, then the manufacturing cost is reduced, but the wire harness becomes more susceptible to heat damage
Solution Approach 1:
The first wire member is positioned in advance to block heat from reaching the second wire member. This preliminary protective arrangement allows the second wire member to use lower-cost insulation materials while still being protected from heat damage, as the heat is already blocked by the first wire member.
Solution Approach 2:
The first wire member serves as an intermediary barrier that prevents direct heat contact with the second wire member. This intermediary protection enables the use of cost-effective insulation materials on the second wire member while maintaining adequate heat resistance through the shielding effect.
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
Suppresses heat effects on the second wire member, allows for cost-effective insulation material selection, reduces fixing members and points, and improves workability during installation.
Implementation Method 1
a metal tube housing the conductor and the insulation coating
Data Source
AI summary
A wire harness for routing in a vehicle in which an exhaust pipe through which exhaust gas flows is attached under a floor, the wire harness including: a first wire to be routed alongside the exhaust pipe; and a second wire to be routed on an opposite side of the first wire to the exhaust pipe, wherein the first wire has: a conductor and an insulation coating covering an outer periphery of the conductor, and a metal tube housing the conductor and the insulation coating.