Cooled Electrical Cable Assembly With Bonded Contact Connection
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Solution Overview
Problem
Existing electrical cable connections in high-voltage applications, such as those used in electric vehicles, face challenges with inflexibility, rigidity, and complexity due to screw connections, crimp connections, and force-fit arrangements, which hinder tolerance compensation and increase production costs.
Innovation Solution
A pre-assembled electrical cable design featuring a cooling channel with an inner conductor bonded to a contact element, allowing for flexible orientation and connection without frictional or form-fitting forces, using material bonding and potentially eliminating separate contact elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If screw connections or crimp connections are used to connect the inner conductor to the contact element, then the connection is mechanically secure, but the connection becomes rigid and inflexible, preventing flexible orientation and tolerance compensation
Solution Approach 1:
The patent replaces traditional mechanical connection methods (screw connections, crimp connections, force-fit arrangements) with material bonding, specifically welding or metallurgical bonding. This substitution eliminates the rigid mechanical interfaces while maintaining strong electrical and mechanical connection, enabling flexible orientation between the cable and connector for tolerance compensation.
Solution Approach 2:
The invention changes the fundamental connection parameter from mechanical interlocking to material-level bonding. By using welding or metallurgical bonding, the connection transitions from a rigid mechanical system to a flexible material-bonded system that can accommodate orientation variations and tolerances while maintaining connection integrity.
2Reliability
If multiple separate components (cable lug, crimp sleeve, bolt) are used to connect the cable to the connector, then the connection is secure, but the device complexity and number of components increases
Solution Approach 1:
The patent merges multiple separate components (cable lug, crimp sleeve, bolt) into a single integrated connection achieved through material bonding. The inner conductor is directly bonded to the contact element without intermediate components, reducing the component count while maintaining or improving connection reliability through the direct material bond.
Solution Approach 2:
The invention extracts and eliminates unnecessary intermediate components from the connection assembly. By removing the cable lug, crimp sleeve, and bolt, and replacing them with direct material bonding between the inner conductor and contact element, the solution simplifies the overall structure while preserving connection integrity.
3Stability of the object's composition
If traditional connection methods are used, then the connection is mechanically stable, but production costs increase due to the complexity of assembly processes
Solution Approach 1:
The patent replaces complex mechanical assembly processes (screw tightening, crimping, bolting) with material bonding processes such as welding. This substitution simplifies the manufacturing process, reduces assembly steps, and lowers production costs while maintaining connection stability through the strong material bond.
4Temperature
If the inner conductor runs along the outer surface of the cooling channel, then heat dissipation is improved, but the connection flexibility and orientation capability are reduced
Solution Approach 1:
The patent replaces rigid mechanical positioning of the inner conductor with material bonding to the contact element. This allows the inner conductor to maintain its optimal position for heat dissipation along the cooling channel while the bonded connection enables flexible orientation of the entire assembly for tolerance compensation.
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
The solution provides a flexible, efficient, and cost-effective connection that enhances heat dissipation, reduces cable weight and electrical resistance, and allows for tolerance compensation, suitable for high-voltage applications.
Implementation Method 1
the inner conductor (4) is materially bonded to a surface (11) of the contact element (9) facing away from the cooling channel (2)
Implementation Method 2
a cooling channel (2) extending along a central axis (M) of the cable (1)... To dissipate the heat generated in the cables and connectors, cooled high-voltage cables are sometimes used
Implementation Method 3
connected to a cooling circuit, through which a coolant flows to transport the heat
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a pre-assembled electrical cable (1). The cable (1) has a cooling channel (2) extending along the central axis (M) of the cable (1) and at least one inner conductor (4) running along the outer surface of the cooling channel (2). The cable (1) further comprises a cable sheath (7) containing the inner conductor (4) and the cooling channel (2) and a contact element (9) for an electrical connector (10), wherein the contact element (9) is electrically and mechanically connected to at least one section of the inner conductor (4) exposed by the cable sheath (7). It is provided that the inner conductor (4) is either bonded to the contact element (9) or compacted in a plate-like form to create the contact element (9).