Flat Cable Asymmetric Coating for Direct Screwing
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Solution Overview
Problem
The use of terminal bolts on flat cables in automotive applications is hindered by the need for rotational symmetry during assembly, which is difficult in complex geometries, and base metal materials like aluminum are prone to galvanic corrosion and deformation, making direct screwing challenging.
Innovation Solution
A continuous method of manufacturing flat cables where a first metal cable is coated with a second metal using processes like roll bonding, friction coating, or powder coating, followed by insulation, allowing for direct screwing and minimizing material usage by coating only the required areas, ensuring compatibility with connection parts and reducing corrosion risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If terminal bolts are used to connect flat cables, then connection reliability is improved, but assembly complexity increases due to rotational symmetry requirements
Solution Approach 1:
The patent applies asymmetry by coating only one side of the flat cable with a second metal that is compatible with connection bolts. This asymmetric coating configuration eliminates the need for rotational symmetry during assembly, allowing the cable to be connected in any orientation while maintaining connection reliability. The asymmetric design resolves the contradiction by enabling reliable connections without imposing complex assembly requirements.
Solution Approach 2:
The patent applies preliminary action by pre-coating the flat cable with a compatible metal layer before assembly. This preliminary coating action ensures that when the connection bolt is applied, immediate chemical compatibility and electrical conductivity are achieved without requiring complex alignment or rotational positioning during the connection process, thereby reducing assembly complexity while maintaining reliability.
2Weight of moving object
If base metal materials like aluminum are used for flat cables, then weight is reduced, but galvanic corrosion resistance deteriorates
Solution Approach 1:
The patent applies composite materials by creating a bimetallic structure where a first metal (such as aluminum) serves as the base material for the flat cable, providing lightweight properties, while a second metal coating is applied to the surface to provide galvanic corrosion resistance and compatibility with connection bolts. This composite approach allows the cable to maintain the weight advantages of aluminum while gaining the corrosion resistance of the protective coating layer.
Solution Approach 2:
The patent applies local quality by coating only the specific areas of the flat cable that require enhanced properties. The second metal coating is applied to the surface regions that will contact connection bolts or are exposed to corrosive environments, while the bulk material retains the lightweight properties of the base metal. This localized treatment resolves the contradiction by providing corrosion resistance where needed without compromising the overall weight advantage.
3Reliability
If complete coating of flat cable is applied, then compatibility with connection parts is improved, but material usage increases
Solution Approach 1:
The patent applies local quality by coating only the specific regions of the flat cable that require enhanced compatibility with connection parts. Instead of applying a complete coating to the entire cable surface, the second metal is applied selectively to the areas that will contact connection bolts or are exposed to corrosive environments. This localized coating approach maintains compatibility where needed while minimizing material consumption and reducing costs.
4Reliability
If rotational symmetry is required for connection bolts, then connection reliability is improved, but ease of operation deteriorates in complex geometries
Solution Approach 1:
The patent applies asymmetry by configuring the flat cable with a non-symmetric coating pattern, where only one side or specific regions are coated with the second metal. This asymmetric configuration eliminates the requirement for rotational symmetry during assembly, allowing connection bolts to be applied in any orientation. The asymmetric design maintains connection reliability through the coated regions while dramatically improving ease of operation in complex geometries by removing alignment constraints.
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 the production of flat cables suitable for direct screwing with connection bolts, reducing assembly complexity and minimizing galvanic corrosion by using environmentally friendly coating methods, while maintaining high current-carrying capacity and mechanical integrity.
Implementation Method 1
The flat cable is coated with a second metal material different from the first metal material in a continuous process, in particular by friction under pressure
Implementation Method 2
The flat cable is coated with a second metal material different from the first metal material in a continuous process, in particular by friction under pressure
Implementation Method 3
The flat cable is coated with a second metal material different from the first metal material in a continuous process
Implementation Method 4
The flat cable, which was initially coated in this way, is coated with an insulating layer
Data Source
Figure 1
Figure 2~3
AI summary
The present invention relates to a method for manufacturing a cable comprising the steps of: providing a flat conductor made of a first metallic material, coating the provided flat conductor with a second metallic material different from the first metallic material, and applying an insulating layer to the flat conductor including the coating.