Wire Harness Non-Metallic Braided Shield Weight Reduction
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Solution Overview
Problem
The existing braided wire shielding structures are heavy and costly due to the use of metallic fibers, which is a concern for weight reduction in automobile components and is exacerbated by rising steel prices.
Innovation Solution
A wire harness is designed using a tubular braided wire made from non-metallic fibers such as carbon fibers or conductive resin fibers, which are lighter and less expensive, integrated with a conductive resin shell for terminal connections, allowing the braided wire to be lighter and more cost-effective.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metallic fibers are used to form the braided wire, then the shielding effectiveness and structural strength are maintained, but the weight and cost of the wire harness increase
Solution Approach 1:
The patent changes the material parameter of the braided wire from metallic fibers to non-metallic conductive fibers. This fundamental material substitution maintains the electrical conductivity and shielding effectiveness while significantly reducing the weight and cost of the wire harness assembly.
Solution Approach 2:
The patent employs composite materials by combining non-metallic fibers with conductive properties. The conductive resin shell integrated with the non-metallic braided wire creates a composite structure that achieves both electromagnetic shielding and weight reduction objectives simultaneously.
2Reliability
If metallic fibers are used to form the braided wire, then the shielding performance is ensured, but the cost of the wire harness increases due to rising steel prices
Solution Approach 1:
The patent changes the material parameter from expensive metallic fibers to cost-effective non-metallic conductive fibers. This substitution directly addresses the cost increase issue while preserving the essential shielding performance through the conductive properties of the non-metallic material.
Solution Approach 2:
The patent adopts cheaper non-metallic fiber materials that can be produced at lower cost compared to metallic fibers. The conductive resin shell provides a durable connection structure, allowing the use of more economical fiber materials without compromising overall system reliability.
3Weight of moving object
If non-metallic fibers are used to form the braided wire, then the weight and cost are reduced, but the electrical conductivity and shielding effectiveness may be compromised
Solution Approach 1:
The patent uses composite materials where non-metallic fibers are combined with conductive resin. The conductive resin shell acts as a matrix that provides electrical conductivity pathways, compensating for the lower inherent conductivity of non-metallic fibers and ensuring adequate shielding effectiveness.
Solution Approach 2:
The patent applies different material properties to different parts of the structure. The braided wire portion uses lightweight non-metallic fibers for weight reduction, while the terminal connection portions use conductive resin to ensure electrical conductivity and shielding effectiveness at critical connection points.
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
This solution reduces the weight and cost of the braided wire, contributing to improved fuel efficiency and cost savings while maintaining effective electromagnetic shielding.
Implementation Method 1
the terminal portion of the tubular braided wire is integrally molded with an inserted portion of the conductive resin shell
Implementation Method 2
the element wires are electrically conductive and made of non-metallic fibers
Data Source
Figure 1A~1B
Figure 2
Figure 3A~3B
AI summary
Herein disclosed is a wire harness capable of reducing weight and cost of a braided wire, and a total weight and cost of the wire harness. A wire harness 32 is equipped with three high voltage cables 39 and a braided wire 40 that collectively shields the three high voltage cables 39. A braided wire formed from strands of extra fine conductive element wires made of non-metallic fibers that are lighter than metallic fibers is used as the braided wire 40. Carbon fibers or conductive resin fibers formed by mixing a conductive material into a resin material are used as the element wires. In the braided wire 40, the element wires are formed from; for instance, non-metallic fibers that are lighter than metallic fibers per unit length. Consequently, the element wires become lighter than the element wires made of metallic fibers and impervious to a run-up in steel prices.