Deflection-Containing Electrical Conductor for Vehicle Power Systems
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Solution Overview
Problem
Conventional electrical connectors, especially those used in vehicles, face premature failure due to vibration-induced degradation of terminal contacts, leading to reduced conductivity and flexibility issues when handling high amperages.
Innovation Solution
An electrical conductor with multiple orthogonal deflections and cutouts is designed to enhance vibration damping, formed from conductive strips or layers of sheet material, which engage electrical terminals and are suited for vehicle power systems, incorporating polymeric insulators and specific material choices like copper alloys for improved longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If larger cross-sectional area conductors are used to communicate large amperages, then current carrying capacity is improved, but flexibility deteriorates
Solution Approach 1:
The conductor is divided into multiple parallel strips (e.g., three strips) instead of using a single solid bar. This segmentation maintains the total cross-sectional area needed for high current capacity while introducing flexibility through the multiple separate elements that can bend independently.
Solution Approach 2:
The patent uses thin strip configurations rather than thick solid conductors. These thin strips provide the necessary flexibility for installation and movement while maintaining adequate current carrying capacity through the combined cross-sectional area of multiple strips.
2Stability of the object's composition
If conventional rigid electrical connectors are used in vibratory environments, then structural stability is improved, but terminal contact reliability deteriorates due to vibration-induced degradation
Solution Approach 1:
The conductor strips are formed with deflections or curves rather than being completely straight. These deflections allow the conductor to absorb and dampen vibrations through elastic deformation, reducing vibration-induced stress on terminal contacts while maintaining structural integrity.
Solution Approach 2:
The patent modifies the physical parameters of the conductor by introducing deflections with specific heights and radii of curvature. These parameter changes enable the conductor to dynamically respond to vibrations, transforming rigid structural stability into a more resilient configuration that protects terminal contacts.
3Reliability
If multiple deflections are added to the conductor strips, then vibration damping is improved, but device complexity increases
Solution Approach 1:
The deflections are formed as simple curved sections with defined radii of curvature and heights. These geometric features provide effective vibration damping while maintaining relatively simple manufacturing processes through standard forming operations, avoiding excessive complexity.
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 conductor effectively dampens vibrations, prolonging electrical performance and reducing terminal contact failures, while maintaining operational efficiency in confined vehicle power system environments.
Implementation Method 1
Multiple vibration damping deflections orthogonal to the conductor length
Implementation Method 2
The deflections are readily provided within the plane defined by the cutouts or extend above the plane
Data Source
AI summary
An electrical conductor is provided that includes at least one strip of conductive material defining a length and having a first end with a first cutout and a second end having a second cutout. The cutouts engage electrical terminals. The at least two deflections are orthogonal to the length of the strip. The deflections are located between the first cutout and the second cutout and are in plane or out of plane of the cutouts. The electrical conductor is particularly well suited for interconnection of batteries associated with a vehicle power system.