Wire Harness Meshed Sheath Heat Dissipation
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Solution Overview
Problem
High voltage electric wires in hybrid and electric vehicles experience significant temperature increases due to high currents, necessitating improved heat dissipation solutions.
Innovation Solution
A wire harness design featuring a core wire with a non-sheathed portion covered by a meshed sheath member made from reinforced fibers, which enhances heat dissipation and wear resistance, allowing for flexible arrangement at bent portions and collective coverage of multiple wires with a single sheath member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulation sheath covers the entire electric wire, then electrical insulation is improved, but heat dissipation deteriorates
Solution Approach 1:
The insulation sheath is removed from a specific intermediate portion of the electric wire, creating a non-sheathed portion. This segmentation allows different sections of the wire to have different functions: the sheathed portions maintain electrical insulation while the non-sheathed portion enables heat dissipation through the meshed sheath member.
Solution Approach 2:
The wire structure is made non-uniform by providing a non-sheathed portion at the intermediate section while maintaining insulation sheaths at the ends. This local quality change allows heat dissipation where needed (intermediate portion) while preserving electrical insulation where required (end portions).
2Temperature
If a meshed sheath member is used instead of solid insulation sheath, then heat dissipation is improved, but wear resistance deteriorates
Solution Approach 1:
The sheath member is constructed from heat-resistant synthetic resin fibers that provide both the meshed structure for heat dissipation and sufficient wear resistance for protection. This composite material approach resolves the contradiction by finding a material that satisfies both requirements simultaneously.
3Ease of operation
If the sheath member contacts the exterior member at bent portions, then flexibility is improved, but wear resistance deteriorates
Solution Approach 1:
The sheath member is positioned and secured at the bent portion before final assembly, ensuring proper contact with the exterior member. This preliminary positioning prevents excessive movement and friction that would cause wear, while still allowing the necessary flexibility for routing through bent portions.
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 design improves heat dissipation by approximately 5% to 10% compared to conventional insulation sheaths, while maintaining structural integrity and reducing the number of parts required.
Implementation Method 1
the non-sheathed portion is covered by the meshed sheath member so that heat of the core wire is released to the outside through the mesh
Data Source
AI summary
A wire harness has: wires each including a core wire that is formed from a conductor and an insulating covering that covers the outer periphery of the core wire; and an exterior material and a braided member, into which the wires are inserted. Each wire has a removed-covering section where the insulating covering has been removed partway in the longitudinal direction. The removed-covering section is covered by a webbed covering member, the outer periphery of which has insulating properties.