Electric Cable Structural Body With Insulating Windows
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric cable connection systems face challenges in accurately and efficiently connecting conductors at desirable intersection points without the need for dedicated jigs, leading to potential errors and increased costs due to the use of crimp terminals and complex wiring patterns.
Innovation Solution
An electric cable structural body with exposed conductor groups intersecting and overlapping, featuring an insulating unit with windows at specific positions for conductor intersection points, allowing for precise and efficient connection through methods like electric resistance welding, laser welding, or sonic vibration, eliminating the need for crimp terminals and dedicated jigs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If crimp terminals are used to connect conductors at intersection portions, then connection can be achieved, but the number of components increases and production efficiency decreases
Solution Approach 1:
The patent removes the insulating cover from specific portions of the insulating member to create openings, extracting the need for separate crimp terminals. The conductor connection is achieved directly through these openings without additional components, thereby improving production efficiency while maintaining connection capability.
Solution Approach 2:
The patent merges the functions of the insulating member and the connection structure into a single integrated component. The insulating member itself provides both insulation and the mechanism for conductor connection through its openings, eliminating the need for separate crimp terminals and reducing component count.
2Ease of manufacture
If crimp terminals are used to connect conductors, then connection can be achieved, but the number of components increases
Solution Approach 1:
The patent extracts the connection function from separate crimp terminals and integrates it into the insulating member itself. The openings in the insulating member directly enable conductor connection, reducing the number of components while maintaining ease of manufacture.
Solution Approach 2:
The patent combines the insulating function and connection function into a single integrated insulating member. This merging eliminates the need for separate crimp terminals, reducing device complexity while preserving the connection capability.
3Ease of operation
If intersection portions are selected and connected manually by checking specification manuals, then connection can be made, but the process becomes troublesome and errors may occur
Solution Approach 1:
The patent performs preliminary action by pre-defining the connection locations through the opening positions in the insulating member during manufacturing. This eliminates the need for manual selection and checking of specification manuals during operation, reducing errors and improving reliability while maintaining ease of operation.
Solution Approach 2:
The insulating member with pre-positioned openings serves itself to guide the connection process. The openings automatically indicate where conductors should be connected, eliminating the need for external specification manuals or manual selection, thereby improving both ease of operation and reliability.
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 ensures accurate and efficient connection of conductors at desired points, reducing production costs and improving reliability by stabilizing connections under varying environmental conditions, such as vibration and temperature changes, while allowing for flexible wiring patterns and compact designs.
Implementation Method 1
an insulating unit provided between the first direction exposed conductor group and the second direction exposed conductor group at the intersection overlap portion, the insulating unit electrically insulating the exposed conductor portions from each other
Implementation Method 2
the windows passing through the insulating unit such that the exposed conductor portions intersecting each other face each other via the windows; and the exposed conductor portions facing each other via the windows are connected to be conductive to each other
Data Source
AI summary
A first direction exposed conductor group includes a plurality of exposed conductor portions of a first flat cable, and a second direction exposed conductor group includes a plurality of exposed conductor portions of a second flat cable. The plurality of exposed conductor portions are located parallel to each other, and the plurality of exposed conductor portions are located parallel to each other. The first direction exposed conductor group and the second direction exposed conductor group intersect and overlap each other to form an intersection overlap portion. An intersection insulating film is provided between the first direction exposed conductor group and the second direction exposed conductor group at the intersection overlap portion. The exposed conductor portions and the exposed conductor portions facing each other via windows of the intersection insulating film are connected to be conductive to each other. Thus, an electric cable structural body is provided.