Wire Harness Heat Dissipation via Segmented Protective Tubes
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Solution Overview
Problem
The increasing current flow in wire harnesses for hybrid and electric vehicles has led to enhanced heat generation, necessitating improved heat dissipation capabilities in these systems.
Innovation Solution
A wire harness design incorporating independently formed protective tubes and a heat dissipation member, where the protective tubes are arranged to minimize thermal resistance and the heat dissipation member is interposed between them to enhance heat transfer, is proposed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple wires are covered collectively by a single protective tube, then the protective function and electromagnetic shielding are improved, but the heat dissipation ability deteriorates
Solution Approach 1:
The single protective tube is divided into multiple separate protective tubes, with each wire having its own protective tube. This segmentation allows heat from each wire to dissipate independently through its own protective tube surface, preventing heat accumulation that would occur in a bundled configuration, while still providing protective function and electromagnetic shielding for each individual wire.
2Power
If the amount of current flowing in wires is increased, then the power transmission capability is improved, but the heat generation increases
Solution Approach 1:
The harmful heat generated by high current flow is converted into a manageable thermal management issue by using the protective tubes as heat dissipation surfaces. The protective tubes, which provide necessary protection and shielding, also serve as thermal pathways to dissipate the heat generated by high current, transforming a potential problem into a functional solution.
3Reliability
If wires are inserted into protective tubes for protection, then the protective function is improved, but the heat dissipation path is restricted
Solution Approach 1:
The protective tubes are designed to serve multiple functions simultaneously: providing mechanical protection for the wires, offering electromagnetic shielding, and acting as heat dissipation surfaces. This multi-functionality resolves the contradiction by making the protective structure itself the heat dissipation pathway, eliminating the need for separate heat management components.
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 design effectively improves heat dissipation by reducing thermal resistance and efficiently emitting heat generated by the wires, thereby maintaining lower temperatures and enhancing the overall performance of the wire harness.
Implementation Method 1
a heat dissipation member that is interposed between the protective tubes and that dissipates heat generated by the wires
Data Source
AI summary
A wire harness including: a plurality of wires each including a core wire and an insulative covering that covers an outer periphery of the core wire; a plurality of protective tubes into which the plurality of wires are respectively inserted, and which are each formed independently; and a fixing member that gathers together and fixes the plurality of protective tubes.