Composite Sensor Conductor Thermal Stress Reduction
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Solution Overview
Problem
Existing solutions for sensors and actuators in motor vehicles, such as those in trucks, face challenges with mechanical and thermal stress due to high temperatures and material expansion differences, particularly at the electrical connection points, leading to inefficiencies and increased costs.
Innovation Solution
A device with a sensor or actuator featuring an electrical conductor with a core made of a material having lower thermal conductivity than its jacket, where the core is typically made of a mechanically stable material like steel and the jacket of a highly conductive material like copper, reducing heat input and mechanical stress while maintaining sufficient electrical and mechanical coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a high-strength copper line is used, then electrical conductivity is improved, but thermal conductivity increases leading to higher thermal stress
Solution Approach 1:
The patent applies composite materials by combining copper core (for electrical conductivity) with steel jacket (for thermal isolation and mechanical strength). This composite structure resolves the contradiction by allowing the copper to provide necessary electrical conductivity while the steel jacket reduces thermal conductivity, thereby lowering thermal stress on the sensor/actuator components.
2Temperature
If pure steel lines are used, then thermal conductivity is reduced, but manufacturing cost increases
Solution Approach 1:
The patent uses a composite structure with copper core and steel jacket, where the copper provides cost-effective electrical conductivity and the steel provides thermal isolation. This approach is more economical than using pure steel lines while still achieving the desired thermal stress resistance, as the steel jacket can be made thinner compared to pure steel constructions.
Solution Approach 2:
The patent applies local quality by providing steel jacket specifically at the connection area where thermal stress is most critical, while the rest of the cable can use different materials or structures. This localized application of steel reduces overall manufacturing cost while maintaining thermal stress resistance where needed most.
3Strength
If thick electrical conductors are used, then mechanical strength is improved, but flexibility decreases
Solution Approach 1:
The patent uses composite materials with copper core providing flexibility and electrical conductivity, while the steel jacket provides mechanical strength. The steel jacket can be designed with appropriate thickness and structure to maintain flexibility while providing necessary mechanical protection, resolving the contradiction between strength and flexibility.
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 significantly reduces heat input and mechanical stress, enhancing the durability and resistance to thermal loads, particularly in applications like anti-lock braking systems, while maintaining low costs and efficient electrical conductivity.
Implementation Method 1
an electrical single conductor with a core made of a first material and a jacket made of a second material and that first material has a lower thermal conductivity than the second material
Data Source
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AI summary
The invention relates to a device which comprises a sensor or actuator and coupling means for electrically and mechanically coupling the sensor or actuator. The coupling means comprise an electrical single conductor (30) having a core (31) from a first material and a jacket (32) from a second material, the first material having a lower thermal conductivity than the second material.