Electrical Connection Bracket for Motor Vehicle Battery Line
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Solution Overview
Problem
In motor vehicle on-board networks, existing electrical connection systems face challenges with high contact resistance and corrosion, particularly when using aluminum cables, leading to ohmic losses and heating issues, and require a solution for decentralized energy distribution with minimal electrical losses.
Innovation Solution
An electrical connection console with a metal flat part and connecting bolt welded to the conductor in a non-insulated central area, forming an enlarged connection surface for low-loss current flow, using ultrasonic or friction welding to minimize contact resistance and prevent corrosion, and incorporating insulation to protect from environmental influences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an electrical tap is created on the main power line, then electrical outlets can be provided for consumers, but contact resistance increases and ohmic losses occur
Solution Approach 1:
The patent transitions from point-contact taps to a surface-contact interface by creating a flat connection area on the conductor. This dimensional change from 0D point contact to 2D surface contact significantly reduces contact resistance and enables multiple connection points without increasing ohmic losses
Solution Approach 2:
The main power line is segmented into multiple connection points along its length, allowing decentralized energy distribution. Each connection point can serve different consumers independently, providing versatility while maintaining low overall resistance through the extended connection surface
2Adaptability or versatility
If an electrical tap is created on the main power line, then electrical outlets can be provided for consumers, but corrosion risk increases
Solution Approach 1:
The patent creates a controlled connection environment by covering the connection area with insulation material, protecting the metal-conductor interface from oxygen and moisture. This inert environment prevents oxidation and corrosion at the tap locations while allowing multiple outlets to be provided
3Weight of moving object
If aluminum cables are used, then weight is reduced, but contact resistance becomes high due to oxidation
Solution Approach 1:
The insulation material creates a protective environment around the aluminum conductor connection area, preventing oxidation. This allows aluminum cables to maintain their low weight advantage while avoiding the contact resistance problem that would otherwise result from aluminum oxidation
Solution Approach 2:
By expanding the connection from a point contact to a surface area contact on the aluminum conductor, the patent reduces current density at the interface. This dimensional change lowers contact resistance and prevents the heating and oxidation problems associated with point contacts on aluminum cables
4Adaptability or versatility
If the cable is interrupted for taps, then electrical outlets can be provided, but conductance of the battery line is negatively influenced
Solution Approach 1:
Instead of interrupting the cable to create taps, the patent creates connection surfaces along the cable length. This allows multiple outlets to be provided without breaking the continuous conductive path, maintaining full conductance and reliability of the battery line
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
Enables efficient, low-loss electrical tapping along the battery line with minimal interruption to the cable's conductivity, allowing for decentralized energy distribution and reduced risk of corrosion, while maintaining the cable's integrity and conductivity.
Implementation Method 1
using ultrasonic or friction welding to minimize contact resistance
Implementation Method 2
using ultrasonic or friction welding to minimize contact resistance
Data Source
Figure 1a~1c
Figure 2~3d
Figure 4~6
AI summary
The invention relates to an electrical connection bracket for a motor-vehicle electrical system, comprising a cable (2) having a metal conductor (4) and comprising an electrical tap (12) electrically and mechanically connected to the conductor (4). A decentralized electrical-system structure is made easier in that the tap (12) is formed of a metal flat part (20) and a metal connection pin (12) bonded to the flat part (20) and that the flat part (20) is connected to the conductor (4) in a bonded manner in a connection region (10) of the conductor (4), wherein the connection region (10) is arranged between the ends of the cable (2).