Electrical Distributor Rigid Current Rails Plug Connection

Solution Overview

Problem

Electrical distributor arrangements for motor vehicles are cumbersome and expensive due to the technical complexity of connecting attachment lines to power bus lines, which requires individual cable connections within the housing after cable ends are connected.

Innovation Solution

The use of rigid current rails allows for pre-installation and connection to electrical terminals, enabling easy attachment of lines through screw connections, ring cable lugs, or welded connections, reducing technical outlay and manufacturing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If individual cable connections are used to connect attachment lines to power bus lines within the housing, then electrical connection is achieved, but the installation becomes cumbersome and expensive

Engineering Contradiction:

Improveelectrical connectionVSAvoidinstallation complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple individual cable connections into a single plug connection that interfaces with a socket in the housing. The attachment lines are bundled together and connected via a plug that mates with a socket containing the power bus lines, eliminating the need for separate wire-bonded connections for each attachment line to the power bus line.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The plug connection is pre-assembled with all attachment lines connected to the plug terminals before insertion into the housing. This preliminary assembly allows the attachment lines to be connected to the power bus lines through a single plug insertion action, rather than requiring individual connections to be made after the cable ends are connected to the housing.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If wire-bonded connections are used to electrically contact attachment lines to the power bus line, then electrical connection is achieved, but the manufacturing cost increases

Engineering Contradiction:

Improveelectrical connectionVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces multiple expensive wire-bonded connections with a single plug connection assembly. The plug contains all necessary electrical contacts integrated into a modular unit that connects to the socket in one action, significantly reducing manufacturing complexity and cost compared to individual wire bonding operations for each attachment line.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The plug serves as an intermediary component that facilitates electrical connection between the attachment lines and the power bus lines without requiring direct wire bonding. The plug acts as a mediator that simplifies the connection process while maintaining reliable electrical contact through its integrated contact structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If attachment lines are contacted in the interior of the distributor housing after cable ends are connected, then electrical distribution is achieved, but the installation process becomes cumbersome

Engineering Contradiction:

Improveelectrical distributionVSAvoidinstallation ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The plug connection is pre-assembled with all attachment lines connected to the plug terminals before insertion into the housing. This preliminary assembly allows the attachment lines to be connected to the power bus lines through a single plug insertion action, rather than requiring individual connections to be made after the cable ends are connected to the housing.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent combines multiple individual cable connections into a single plug connection that interfaces with a socket in the housing. The attachment lines are bundled together and connected via a plug that mates with a socket containing the power bus lines, eliminating the need for separate wire-bonded connections for each attachment line to the power bus line.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS10017063B2Electrical distributor arrangement

Publication Date: 2018.07.10 DR ING H C F PORSCHE AG

AI summary

An electrical distributor arrangement, in particular for electrically driven motor vehicles, having a housing which has two electrical terminals which are connectable in each case to an external electrical energy source, a multiplicity of through lines which are connected at their ends in each case to one of the terminals, and a multiplicity of electrical attachment lines which are led into the housing for the purposes of electrically contacting a multiplicity of electrical consumers with the through lines, wherein the through lines are in the form of rigid current rails, and wherein the attachment lines are fixedly connected in each case to one of the current rails.