Conductive Cable with Crushed Conductor for Flexible Vehicle Wiring
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Solution Overview
Problem
The existing conductive cable wiring structures for hybrid and electric vehicles face challenges in reducing the diameter of stranded electric cables, which increases costs and complicates bending, making it difficult to efficiently use installation space and reduce weight.
Innovation Solution
A conductive cable configuration that combines a single-core electric cable with a stranded electric cable, where the single-core cable's conductor is exposed and crushed to form a flat plate, allowing the stranded wires to connect to it, enabling flexible bending and reduced diameter, and using a shield pipe with a metal braided portion for improved bendability and connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If stranded electric cables are used throughout the entire wiring path to ensure bendability, then the cable can be easily bent to follow the wiring path, but the diameter of the cable increases and the cost increases
Solution Approach 1:
The conductive cable is divided into two distinct sections: a shield pipe section with single-core electric cables for rigid protection and electrical conductivity, and a metal braided portion with stranded electric cables for flexible bending operations. This segmentation allows each section to be optimized for its specific function without compromising the other.
Solution Approach 2:
Different cable structures are applied to different locations along the cable assembly. The single-core cables with metal shielding are used where structural integrity and EMI protection are needed, while stranded cables are used only at the metal braided portion where frequent bending and flexibility are required.
2Ease of operation
If stranded electric cables are used throughout the entire wiring path to ensure bendability, then the cable can be easily bent, but the cost increases due to the stranding process
Solution Approach 1:
The cable assembly is segmented into two parts with different construction methods. The majority of the cable length uses cost-effective single-core cables, while only the terminal portion requires the more expensive stranding process, thereby reducing overall manufacturing costs while maintaining necessary flexibility.
Solution Approach 2:
The expensive stranded cable construction is applied locally only where flexibility is needed (at the metal braided portion for connection operations), rather than throughout the entire cable length, optimizing the cost-performance ratio.
3Volume of moving object
If single-core electric cables are used to reduce diameter, then the cable diameter is reduced and space is saved, but the bendability at the end portion becomes poor
Solution Approach 1:
The cable is segmented into a rigid shield pipe section containing single-core cables and a flexible metal braided section containing stranded cables. This allows the majority of the cable to have small diameter while the connection end maintains excellent bendability.
Solution Approach 2:
Different cable structures are assigned to different functional zones: single-core cables in the shield pipe for space efficiency and stranded cables at the metal braided portion for operational flexibility, ensuring each location has the appropriate cable properties.
4Volume of moving object
If the shield pipe diameter is reduced to save space, then space utilization is improved, but it becomes difficult to insert and connect cables
Solution Approach 1:
The connection function is segmented from the main cable body and assigned to the metal braided portion with stranded cables. This allows the shield pipe to maintain a small diameter while the connection end provides ample space and flexibility for cable insertion and termination operations.
Solution Approach 2:
The metal braided portion is designed with larger diameter and flexible stranded construction specifically at the connection location, allowing easy cable insertion and termination while the rest of the shield pipe maintains compact dimensions for space-efficient installation.
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 ensures favorable bendability at the end portion, reduces the cable diameter, enhances connection reliability, and allows for efficient use of space and weight reduction in vehicle wiring, while maintaining insulation and water-stop properties.
Implementation Method 1
the exposed conductor being crushed to one side in a thickness direction into a flat plate shape to form a crushed portion
Implementation Method 2
electrically connecting the conductor and the wires by welding the end surface of the conductor and the end surfaces of the wires
Data Source
AI summary
A conductive cable includes a single-core electric cable and a stranded electric cable. The single-core electric cable is constituted by a single conductor covered with a coating. The stranded electric cable is constituted by a plurality of stranded wires that are covered with a coating. The stranded electric cable is electrically connected to at least one of two end portions in a length direction of the single-core electric cable. The coating is stripped and the conductor is exposed at the at least one end portion of the single-core electric cable, the exposed conductor being crushed to one side in a thickness direction into a flat plate shape to form a crushed portion, and the wires of the stranded electric cable being connected to the crushed portion.