Coaxial Prefabricated Cable Assembly With Integrated Contact Plates
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Solution Overview
Problem
Existing cable assembly technologies for vehicles, particularly for high-current applications, face challenges in simplifying the manufacturing process, reducing material and component count, while maintaining mechanical integrity and low electrical resistance.
Innovation Solution
A prefabricated cable design featuring coaxially arranged conductors with a base body incorporating electrically conductive plate-shaped elements and contact sockets, allowing for a simpler assembly process and reduced component count, while ensuring robust mechanical and electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If flat conductors or single conductors are used for high-current applications, then current transmission capability is improved, but bending process complexity and manufacturing cost increase due to rigidity requirements
Solution Approach 1:
The conductor is segmented into multiple fine strands (7x7 or 19x7 strand structure) instead of using a single solid conductor. This segmentation allows the cable to be flexible and easily bendable while maintaining high current transmission capability, eliminating the need for complex bending processes and reducing manufacturing complexity
Solution Approach 2:
The invention uses composite strand structures combining copper or aluminum conductors with specific insulation materials (cross-linked polyethylene or thermoplastic elastomer). This composite structure provides both the electrical performance needed for high-current applications and the mechanical flexibility required for simple bending processes
2Ease of manufacture
If solid conductors are used instead of stranded wires, then manufacturing simplicity is improved, but connection difficulty and electrical resistance increase
Solution Approach 1:
The conductor is divided into multiple flexible strands rather than using a solid conductor. This segmentation maintains ease of manufacturing through standardized stranded wire production while dramatically improving connection reliability by allowing better contact formation and reducing connection resistance at terminal points
Solution Approach 2:
The invention changes the structural parameters of the conductor from solid to stranded configuration, and selects specific material parameters (copper or aluminum with appropriate insulation). This parameter optimization simultaneously achieves manufacturing simplicity and high connection reliability with low electrical resistance
3Object-affected harmful factors
If coaxial conductors are used, then electromagnetic compatibility is improved, but assembly complexity increases without simplified bending process
Solution Approach 1:
The coaxial cable structure is implemented using segmented stranded conductors for both inner and outer conductors. This segmentation provides electromagnetic shielding and compatibility benefits while maintaining flexibility that simplifies the bending process and reduces assembly complexity compared to rigid coaxial structures
Solution Approach 2:
The invention uses composite material structures with copper or aluminum conductors combined with appropriate insulation and shielding layers. This composite coaxial structure achieves electromagnetic compatibility while the flexible stranded construction simplifies assembly and bending processes
Data Source
Figure 1~2
Figure 3
AI summary
A prefabricated cable is proposed, comprising a cable having at least two coaxially arranged conductors with a stripped cable end, a base body in which the cable with the stripped cable end is arranged, at least one first electrically conductive plate-shaped element and a second electrically conductive plate-shaped element, wherein at least one first electrically conductive contact socket and a second electrically conductive contact socket are arranged next to one another in the base body. The first electrically conductive plate-shaped element extends between the first contact socket and the stripped cable end, wherein one side of the first plate-shaped element is connected to the first contact socket and another side of the first plate-shaped element opposite the first side is integrally connected to the stripped cable end.The second electrically conductive plate-shaped element extends between the second contact socket and the stripped cable end, with one side of the second plate-shaped element being connected to the second contact socket and another side of the second plate-shaped element, opposite the first side, being integrally connected to the stripped cable end. Furthermore, a method for assembling a cable is proposed.