Plastically Deformed Copper Wire Conductors for BLDC Motors

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Solution Overview

Problem

The manufacturing of electrical conductors for automotive applications is cost-intensive due to the complex production of flat conductors, which are often used for electric current conduction in BLDC motors.

Innovation Solution

Using commercially available round copper wires, which are cut and plastically deformed to create forming sections suitable for various applications, including plug contacts and sealing elements, to produce cost-effective electrical conductors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If flat conductors are used for electric current conduction in BLDC motors, then reliable electrical connections are achieved, but manufacturing costs increase significantly

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces expensive custom-manufactured flat conductors with inexpensive round copper wires that are readily available on the market. These round wires are then plastically deformed into the required shapes to create functional contacts, achieving the same electrical connection reliability at a fraction of the manufacturing cost.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent changes the geometric parameters of the conductor from flat cross-section to round cross-section, and uses plastic deformation to achieve the final contact shape. This parameter change allows using standard round wires instead of custom flat conductors, significantly reducing manufacturing costs while maintaining electrical performance.

Inventive Principle:

Principle #35Parameter changes

2Shape

If custom flat conductors are manufactured, then specific shape requirements are met, but production complexity increases

Engineering Contradiction:

Improveconductor shapeVSAvoidproduction complexity

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The patent uses round copper wires that are pre-manufactured and readily available, eliminating the need for complex custom manufacturing processes. The wires are then plastically deformed into the required shapes through forming operations, which are simpler and more cost-effective than manufacturing custom flat conductors from scratch.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Instead of manufacturing flat conductors and then shaping them, the patent inverts the approach by using readily available round wires and deforming them into the required contact shapes. This inversion simplifies the production process by starting with a standard, easily manufactured form.

Inventive Principle:

Principle #13The other way round (Inversion)

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 method significantly reduces manufacturing costs by utilizing readily available materials and allows for adaptable, reliable electrical connections with substantial cost advantages over traditional flat conductors.

Implementation Method 1

at least one section of the round wire—this section is referred to as 'forming section' in the following—is formed into a predefined desired shape

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Data Source

PatentUS10763014B2Method for producing an electrical conductor

Publication Date: 2020.09.01 MAHLE INT GMBH

AI summary

A method for producing an electrical conductor may include cutting an electrically conductive round wire composed of copper to a predefined desired length and plastically forming the round wire, in at least one forming section, into a predefined desired shape.