Vehicle Cable Sheath Isolating Medium Friction Reduction
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Solution Overview
Problem
Modern vehicles require numerous electrical connections between systems and controllers, leading to extensive installation time and space usage due to the large number of individually laid electrical lines.
Innovation Solution
An electrical line system featuring a common external sheath with an isolating medium that reduces frictional resistance, allowing for efficient laying and mounting of multiple lines together, with the option to shorten sections for specific connections, using a thermoplastic elastomer external sheath and nonwoven fabric isolating medium to minimize pull-off force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If multiple electrical lines are individually laid in the vehicle, then each line can be independently installed and connected, but the installation time and space requirements increase considerably
Solution Approach 1:
Multiple electrical lines are merged into a single common external sheath, forming a bundled cable assembly. This allows multiple lines to be installed together as one unit rather than individually, significantly reducing installation time and effort while maintaining the ability to access individual lines when needed
2Ease of operation
If multiple electrical lines are individually laid in the vehicle, then each line can be independently installed, but the installation space required increases considerably
Solution Approach 1:
Multiple electrical lines are combined into a single common external sheath, reducing the total space required for installation. The bundled configuration allows lines to be routed through tighter spaces and reduces the overall footprint compared to laying multiple separate lines throughout the vehicle
3Strength
If the external sheath tightly surrounds the line arrangements, then mechanical protection is improved, but the pull-off force required to remove the sheath increases
Solution Approach 1:
The internal structure of the external sheath varies along its length, with loose sections providing easy removal capability and tight sections providing mechanical protection. This local variation in sheath tightness allows the same sheath to serve dual purposes: protecting lines where needed and allowing easy access where removal is required
4Strength
If the external sheath is made rigid for protection, then mechanical strength is improved, but flexibility for routing and mounting is reduced
Solution Approach 1:
The external sheath uses materials and construction methods that allow it to change its mechanical properties - being rigid enough to protect lines from damage but flexible enough to be routed around vehicle components and mounted in various locations. The sheath can bend, flex, and adapt to different installation paths while maintaining protective capabilities
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 reduces installation time and space requirements by allowing multiple electrical lines to be jointly laid and mounted efficiently, with reduced frictional resistance and mechanical flexibility for protection against damage.
Implementation Method 1
an isolating medium is arranged within the external sheath, wherein the isolating medium is designed to surround the first line arrangement and the second line arrangement and to keep said line arrangements at a distance from the external sheath in order to reduce a pull-off force when pulling off the external sheath
Data Source
AI summary
An electrical line system for a vehicle, includes a first line arrangement for electrically connecting a first vehicle system to a first controller, a second line arrangement for electrically connecting a second vehicle system to a second controller, and an external sheath which surrounds the first line arrangement and the second line arrangement at least in sections, wherein an isolating medium is arranged within the external sheath, wherein the isolating medium is designed to surround the first line arrangement and the second line arrangement and to keep the line arrangements at a distance from the external sheath in order to reduce a pull-off force when pulling off the external sheath.