Motor Vehicle Cable Connection Using Sleeve-Bolt Torque Separation
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Solution Overview
Problem
Existing electrical connections in automotive applications face challenges in achieving both high mechanical stability and maintaining electrical quality, particularly with copper conductors where high tightening torque risks thread shear-off, and using steel bolts compromises electrical conductivity.
Innovation Solution
The solution involves a metallic sleeve bonded to a connecting part with a steel bolt that has a through-opening and flange, allowing for higher torque without thread shear-off, while maintaining electrical conductivity through the sleeve.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a copper bolt is used to connect copper conductors, then electrical conductivity is maintained, but mechanical stability is reduced due to thread shear-off risk under high tightening torque
Solution Approach 1:
The invention uses a composite structure consisting of a copper sleeve (electrically conductive) and a steel bolt (mechanically strong). The copper sleeve is bonded to the copper conductor, providing excellent electrical conductivity, while the steel bolt provides high mechanical strength and resistance to thread shear-off. This composite approach allows the system to simultaneously achieve both high electrical conductivity and high mechanical stability.
2Strength
If a steel bolt is used to connect conductors, then mechanical stability is improved, but electrical conductivity is reduced due to increased contact resistance
Solution Approach 1:
The copper sleeve acts as an intermediary element between the steel bolt and the copper conductor. The sleeve is bonded to the conductor and receives the bolt, thereby mediating the connection. This intermediary copper component ensures excellent electrical conductivity at the conductor-sleeve interface while allowing the steel bolt to provide high mechanical strength, thus resolving the contradiction between mechanical stability and electrical conductivity.
3Strength
If high tightening torque is applied to a copper bolt, then mechanical connection strength is improved, but thread shear-off occurs
Solution Approach 1:
The invention changes the material parameter of the bolt from copper to steel, which has significantly higher tensile strength and thread shear strength. This parameter change allows the bolt to withstand high tightening torque and dynamic loads without thread shear-off, while the copper sleeve maintains the electrical conductivity that would be compromised by using a steel bolt directly.
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 configuration enhances mechanical stability by allowing higher tightening torque without compromising electrical conductivity, providing a durable and efficient electrical connection.
Implementation Method 1
The sleeve is connected to the connecting part by a material bond
Data Source
AI summary
A connection comprising, a connecting part, a sleeve materially bonded to the connecting part and having a through-opening extending in a longitudinal direction, and a bolt connected to the sleeve and having a bolt shank and a bolt flange, the bolt being crimped with its bolt shank in the longitudinal direction in the through-opening of the sleeve, the bolt is arranged with its bolt flange in a recess arranged at a front face of the sleeve, characterized in that the sleeve is connected to the connecting part by its front face located at the front face end.