Preassembled Coaxial Wire Assembly for High-Current Vehicle Contacting
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Solution Overview
Problem
The challenge lies in preassembling wires for use in vehicles, particularly electric vehicles, that can handle high currents while being lightweight and cost-effective, with existing methods facing issues in electrical contacting and complex bending processes.
Innovation Solution
A preassembled wire configuration featuring coaxially arranged conductors, electrically conductive plate-shaped elements, and contact sockets, where the conductors are materially bonded to the plate-shaped elements, allowing for simpler assembly and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flat conductors or individual conductors are used for high current applications, then the electrical contacting capability is improved, but the bending process becomes elaborate and production becomes costly
Solution Approach 1:
The patent combines multiple conductors into a single coaxial cable structure, integrating the functions of multiple individual conductors into one pre-assembled unit. This eliminates the need for separate bending and assembly operations for multiple conductors, reducing production complexity while maintaining electrical contacting capability.
Solution Approach 2:
The conductors are pre-assembled into a coaxial configuration before installation, with insulation and positioning already in place. This preliminary assembly eliminates the need for elaborate bending processes during final installation, as the conductors are already configured in their final positions.
2Weight of moving object
If solid conductors are used instead of braided materials, then component weight is reduced and costs are saved, but electrical contacting issues arise
Solution Approach 1:
The patent uses solid conductors with optimized material composition and surface treatment to achieve both weight reduction and reliable electrical contacting. The coaxial structure with proper insulation and contact surfaces ensures good electrical connection while maintaining the weight advantages of solid conductors over braided materials.
3Reliability
If coaxial conductors are used for high current applications, then current handling capability is improved, but the bending process becomes simpler and fewer components are needed
Solution Approach 1:
The patent merges multiple conductors into a single coaxial cable assembly, reducing the total number of components and simplifying the manufacturing process. The coaxial structure allows for integrated insulation and positioning, eliminating the need for separate bending operations on multiple individual conductors.
Solution Approach 2:
The coaxial conductors are pre-assembled with insulation and positioning elements before final installation. This preliminary configuration enables direct installation without complex bending processes, as the conductors are already arranged in their final coaxial configuration.
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 enables the production of preassembled wires that can withstand mechanical loads in vehicles, support high currents, and reduce production costs and complexity, while maintaining low electrical resistance.
Implementation Method 1
another side of the first plate-shaped element is materially bonded to the stripped wire end
Data Source
AI summary
A preassembled wire includes a wire having at least two coaxially arranged conductors with a stripped wire end, a main body including the stripped wire end, a first electrically conductive plate-shaped element and a second electrically conductive plate-shaped element. A first electrically conductive contact socket and a second electrically conductive contact socket are arranged in the main body. The first plate-shaped element extends between the first contact socket and the stripped wire end. One side of the first plate-shaped element is connected to the first contact socket and an opposing side of the first plate-shaped element is materially bonded to the stripped wire end. The second plate-shaped element extends between the second contact socket and the stripped wire end. One side of the second plate-shaped element is connected to the second contact socket and an opposing side of the second plate-shaped element is materially bonded to the stripped wire end.