Vehicle Wire Harness Layout With Metal Tube Heat Shielding
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Solution Overview
Problem
Wire harnesses routed alongside exhaust pipes in vehicles are susceptible to heat damage from hot exhaust gases, requiring enhanced heat resistance and efficient routing solutions.
Innovation Solution
A wire harness configuration featuring a first wire with a metal tube housing and insulation coating, and a second wire with a corrugated tube and lower heat resistance insulation, routed on the opposite side of the exhaust pipe, with strategic fixing members to reduce the number of fixing points and improve workability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the wire harness is routed alongside the exhaust pipe to achieve efficient routing, then the routing workability is improved, but the wire harness is exposed to heat from the exhaust pipe causing heat damage
Solution Approach 1:
The patent introduces a heat-resistant coating layer as an intermediary substance between the wire harness and the exhaust pipe. This coating layer acts as a thermal barrier that blocks heat transfer from the exhaust pipe to the wire harness, allowing the wire harness to be routed close to the exhaust pipe without suffering heat damage.
Solution Approach 2:
The patent applies a heat-resistant coating that can be easily applied and removed, serving as a temporary protective measure during high-temperature operation. The coating provides sufficient heat protection for the wire harness to function in the elevated temperature environment near the exhaust pipe.
2Reliability
If the insulation coating is designed with high heat resistance to withstand exhaust pipe heat, then the heat resistance is improved, but the material cost increases
Solution Approach 1:
The patent applies heat-resistant material selectively only in the regions where the wire harness is exposed to high temperatures near the exhaust pipe, rather than using high heat-resistant materials throughout the entire wire harness. This localized application of heat-resistant coating reduces material costs while providing adequate protection where needed.
Solution Approach 2:
The patent uses a composite structure combining standard insulation coating material with a heat-resistant coating layer. The base insulation coating provides electrical insulation, while the additional heat-resistant coating layer provides thermal protection, creating a cost-effective composite solution that combines the benefits of different materials.
3Area of stationary object
If the wire harness is positioned closer to the exhaust pipe to minimize space usage, then the space efficiency is improved, but the ground clearance is reduced
Solution Approach 1:
The heat-resistant coating serves as a protective intermediary that enables the wire harness to be positioned in the limited space closer to the exhaust pipe without compromising the vehicle's ground clearance. The coating provides the necessary thermal protection, allowing optimal space utilization while maintaining safe distances from the ground.
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 solution effectively suppresses heat effects on the wire harness, reduces material costs by allowing flexibility in insulation coating selection, and enhances routing workability by minimizing fixing points and maintaining ground clearance.
Implementation Method 1
the wire harness is required to have heat resistance
Implementation Method 2
an insulation coating covering an outer periphery of the conductor
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.