Conductive Chain for Flexible EV Power Links
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Solution Overview
Problem
Existing electrical connections in electric vehicles, such as braided wires and solid copper bus bars, suffer from current loss during normal operation and pose safety risks during accidents due to potential damage and continuous power flow to metal parts, leading to injuries and fires.
Innovation Solution
A conductive chain formed by interconnected conductive links with a first end portion, a second end portion, and an intermediate portion, made of conductive materials like copper, featuring a concave and convex design for secure connection and elasticity, along with an insulating cover to prevent contact with metal parts, allowing for flexible and safe electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If braided wires are used to achieve flexibility, then the cable becomes flexible, but the cross section is limited causing current loss
Solution Approach 1:
The conductive element is divided into multiple individual conductive links that can move relative to each other, providing flexibility while maintaining a larger effective cross-section for current flow. Each link is a separate segment that contributes to both the flexible structure and the electrical conduction path.
Solution Approach 2:
The patent transitions from a two-dimensional braided structure to a three-dimensional chain of interconnected links. This dimensional change allows the conductive element to achieve flexibility through spatial arrangement of links rather than through thinning the conductor cross-section, thereby maintaining low electrical resistance.
2Reliability
If insulation is used to protect the conductive element, then safety is improved, but the insulation may be damaged during severe impact accidents
Solution Approach 1:
The patent removes the separate insulation layer and integrates the insulating function directly into the conductive links themselves. Each link is formed as an electrically insulating structure that contains the conductive elements, eliminating the vulnerable external insulation layer that could be damaged in accidents.
Solution Approach 2:
The insulating links are designed to absorb and distribute impact forces before they can reach the conductive elements. The insulating material acts as a protective cushion that prevents direct transmission of impact forces to the conductors, maintaining both safety and structural integrity during accidents.
3Loss of energy
If a solid copper bus bar is used, then current loss is reduced, but flexibility is limited and safety during accidents is compromised
Solution Approach 1:
The solid bus bar is segmented into multiple discrete conductive links connected in series. This segmentation provides the flexibility of a cable while maintaining the low-resistance electrical path of a solid conductor, as each link can be optimized for minimal resistance while the overall structure gains flexibility through the articulated connection of segments.
Solution Approach 2:
The patent uses composite construction where insulating material and conductive material are combined in each link. The insulating links provide mechanical flexibility and protection, while the embedded conductive elements maintain low electrical resistance, creating a composite structure that combines the advantages of both flexible cables and solid bus bars.
4Ease of manufacture
If the conductive element is made as a single piece, then manufacturing is simplified, but safety during accidents is reduced due to continuous current flow
Solution Approach 1:
The conductive element is segmented into multiple links with defined connection points between them. These connection points are designed as weak links that can break under excessive force, providing automatic disconnection during accidents. The segmentation is achieved through standardized link designs that can be manufactured independently and assembled into chains of any length.
Solution Approach 2:
The patent designs the system so that individual links or connection points can be discarded (broken off) during accident conditions to stop current flow, while the remaining intact links can be recovered and reused. This controlled discarding mechanism provides safety through automatic circuit interruption while allowing recovery of undamaged components.
Data Source
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AI summary
The present invention is directed to a conductive chain comprising a plurality of conductive links. Each conductive link (10) is made of an electrically conductive material and comprises a first end portion (11) and a second end portion (12). The first end portion (11) and the second end portion (12) are configured so that the first end portion (11) is able to accommodate and hold a second end portion (12) of another conductive link (10) of the conductive chain.