Wire Harness Shield Sealing Against Oxidation Resistance Rise
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Solution Overview
Problem
The electromagnetic shield performance of wire harnesses in hybrid and electric automobiles deteriorates due to oxidation of the electromagnetic shield member, leading to increased electric resistance at the connection points, which are repeatedly heated and cooled.
Innovation Solution
A wire harness design that includes an oxidation suppression layer sealing the fixed portion of the cylindrical member and electromagnetic shield, using a heat-resistant material like silicone sealing material to prevent oxidation and maintain electromagnetic shield performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electromagnetic shield member is fixed to the cylindrical member by a fixing member, then the electromagnetic shield performance is maintained, but the electric resistance increases due to oxidation of the electromagnetic shield member
Solution Approach 1:
An oxidation suppression layer is introduced as an intermediary substance between the electromagnetic shield member and the external environment. This layer prevents oxygen from reaching the electromagnetic shield member, thereby suppressing oxidation while maintaining the electrical connection and electromagnetic shield performance.
Solution Approach 2:
The oxidation suppression layer creates an inert or oxygen-free environment around the electromagnetic shield member at the fixed portion. By replacing the oxidizing atmosphere with an inert barrier, the electromagnetic shield member is protected from oxidation that would otherwise occur during repeated heating and cooling cycles.
2Stability of the object's composition
If the electromagnetic shield member is exposed to air during repeated heating and cooling, then the connection is maintained, but oxidation occurs leading to increased electric resistance
Solution Approach 1:
The oxidation suppression layer is applied in advance to the electromagnetic shield member before the oxidation process can occur. This preliminary protective action prevents oxidation during subsequent repeated heating and cooling cycles, maintaining stable electrical connection and low electric resistance throughout the product lifecycle.
3Device complexity
If no oxidation suppression layer is used, then the device complexity is reduced, but the electromagnetic shield performance decreases over time
Solution Approach 1:
The oxidation suppression layer is implemented as a thin film or coating that conforms to the surface of the electromagnetic shield member. This thin film provides effective oxidation protection without significantly increasing device complexity, maintaining simplicity while ensuring long-term electromagnetic shield performance.
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 oxidation suppression layer effectively prevents oxidation, maintaining the electromagnetic shield performance by reducing the electric resistance at the connection points, even in high-temperature environments.
Implementation Method 1
an oxidation suppression layer that seals a fixed portion of the cylindrical tube and the electromagnetic shield fixed by the fixing member
Data Source
AI summary
A wire harness including: an electric wire; a conductive cylindrical tube through which the electric wire penetrates; a cylindrical electromagnetic shield that surrounds an outer circumference of the electric wire and is fixed to an end of the cylindrical tube; an annular fixing member that fixes the electromagnetic shield to the end of the cylindrical tube; and an oxidation suppression layer that seals a fixed portion of the cylindrical tube and the electromagnetic shield fixed by the fixing member.