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, as they require larger cross-sectional areas for high amperage transmission, making them less flexible and prone to rapid vibration-induced failures.
Innovation Solution
An electrical conductor with multiple orthogonal deflections is designed, featuring cutouts at both ends to engage terminals, allowing for vibration damping and enhanced conductivity, formed from layers of sheet material bonded with lower melting temperature material and deformed into a structure with deflections between the cutouts, which increases the conductor's height profile but improves operational performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thick gauge electrical connector is used to transmit large amperages, then the electrical conductivity is improved, but the flexibility deteriorates and vibration-induced terminal contact failure increases
Solution Approach 1:
The patent introduces deflections (curved sections) into the electrical conductor, transforming it from a straight rigid bar to a flexible conductor with multiple bends. These deflections allow the conductor to flex and absorb vibration while maintaining electrical conductivity, directly resolving the contradiction between conductivity and flexibility.
Solution Approach 2:
The patent adds dimensional complexity by creating deflections that extend above the plane defined by the cutouts. This three-dimensional configuration allows the conductor to accommodate vibration and movement in multiple directions while maintaining its electrical function, addressing both conductivity and flexibility requirements.
2Reliability
If multiple deflections are added to the conductor to damp vibrations, then the terminal contact durability is improved, but the height profile increases
Solution Approach 1:
The deflections are nested within the space between the first and second cutouts, utilizing the existing dimensional space rather than adding external extensions. This nesting approach allows vibration damping functionality to be integrated without proportionally increasing the overall height profile.
Solution Approach 2:
The deflections create a dynamic structure that can adapt its shape in response to vibration frequencies. The conductor can flex and deform to absorb vibration energy, providing terminal contact protection while maintaining a compact overall dimensions when at rest.
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 the risk of terminal contact failure, making it suitable for vehicle power systems despite the increased height profile.
Implementation Method 1
The conductor effectively dampens vibrations, prolonging electrical performance and reducing the risk of terminal contact failure
Implementation Method 2
Multiple strips are optionally used to form a stack and are bent to include at least two deflections orthogonal to the length of the strip
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.