Automotive Wiring Harness Impact Resistance via Localized Shielding
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Solution Overview
Problem
Automotive wiring harnesses connected to high-voltage batteries are prone to short-circuiting during vehicle collisions, which can lead to electrical failures and safety issues.
Innovation Solution
A wiring harness design featuring an elongated tubular electromagnetic shield with a metal pipe and braided members, along with a high-voltage electric wire coated with a braided protector and resin protection tube, which enhances impact resistance and prevents short-circuiting between positive and negative wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a braided protector and resin protection tube are applied to the entire high-voltage electric wire, then impact resistance is improved, but manufacturing cost increases
Solution Approach 1:
The patent applies protective structures (braided protector and resin protection tube) selectively only to portions of the high-voltage electric wire located inside the braided member of the electromagnetic shield, rather than protecting the entire wire length. This localized protection approach reduces material costs and manufacturing complexity while still providing adequate impact resistance where it is most needed - in the region where the wire is most vulnerable to collision impacts during vehicle accidents.
2Reliability
If the protection tube is arranged along the entire length of the high-voltage electric wire, then short-circuit prevention is improved, but device complexity increases
Solution Approach 1:
The resin protection tube is positioned only at specific locations along the high-voltage electric wire - specifically where the wire passes through the braided member of the electromagnetic shield. This localized arrangement reduces the overall complexity of the wiring harness structure while maintaining adequate short-circuit prevention capabilities in the critical regions where insulation damage is most likely to occur during collisions.
3Strength
If the braided protector extends through the metal pipe and braided member, then impact resistance is improved, but manufacturing cost increases
Solution Approach 1:
The braided protector is applied selectively to portions of the high-voltage electric wire that pass through the braided member of the electromagnetic shield, rather than covering the entire wire length including portions inside the metal pipe. This localized protection strategy reduces the amount of braided material required, thereby lowering manufacturing costs while still providing adequate impact resistance in the regions where the wire is most exposed to collision impacts.
Data Source
AI summary
A wiring harness includes an electromagnetic shield and a high-voltage electric wire. The electromagnetic shield includes a metal pipe and a braided member, which is continuous with the metal pipe and includes metal strands. The high-voltage electric wire extends through the metal pipe and the braided member of the electromagnetic shield. The high-voltage electric wire is electrically connected to an automotive high-voltage battery and includes an insulative coating. The high-voltage electric wire includes a braided protector and a resin protection tube. The braided protector is formed by a braid of insulative reinforced fibers and surrounds the insulative coating. The braided protector of the high-voltage electric wire extends from a portion located inside the metal pipe to a portion surrounded by the braided member. The protection tube of the high-voltage electric wire surrounds a portion of the braided protector located inside the braided member.