Flat Conductor Insulation Layout for Bending Resistance
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Solution Overview
Problem
The existing electrical flat conductors for motor vehicles face insulation damage during bending due to high mechanical loads, particularly when using soft insulating materials like PVC, which increases manufacturing costs and requires longer cycle times or additional equipment.
Innovation Solution
The electrical flat conductor features a locally increased insulation wall thickness on one side to enhance mechanical resistance during bending, allowing it to withstand higher loads while minimizing material usage and installation space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bending speed is reduced to decrease forces on insulation, then insulation damage is avoided, but manufacturing cycle time increases and costs increase
Solution Approach 1:
The patent applies local quality by increasing the insulation wall thickness specifically at the narrow sides of the flat conductor core where bending forces concentrate, rather than uniformly increasing thickness everywhere. This localized reinforcement provides the necessary mechanical strength to withstand bending forces during normal production speeds while maintaining overall manufacturing efficiency.
2Strength
If the insulation wall thickness is increased to withstand bending forces, then insulation damage is prevented, but material usage and installation space increase
Solution Approach 1:
The patent implements local quality by providing asymmetric insulation thickness where the wall thickness at the narrow sides exceeds the wall thickness at the broad sides. This ensures that insulation material is concentrated only where mechanically necessary to resist bending forces, optimizing both strength and material efficiency.
Solution Approach 2:
The patent applies asymmetry by designing the insulation layer with different thicknesses at different locations - specifically, the insulation wall thickness at the narrow sides is greater than at the broad sides. This asymmetric design matches the mechanical stress distribution during bending, providing enhanced protection where needed while minimizing overall material usage.
Data Source
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AI summary
The invention relates to an electrical flat conductor (40, 60, 80, 100) for motor vehicles, comprising a flat conductor core (42, 62, 82, 102) made of electrically conductive flat conductor material and an insulating sheath enclosing the flat conductor core (42, 62, 82, 102) made of an insulating material, wherein the height (Hk) of the flat conductor core (42, 62, 82, 102) is less than the width (Bk) of the flat conductor core, wherein the flat conductor core (42, 62, 82, 102) has at least one narrow side (46a-b, 68a-b, 86a-b, 106a-b) that limits the width of the flat conductor core (42, 62, 82, 102) on one side, wherein the at least one narrow side (46a-b, 68a-b, 86a-b, 106a-b) of the flat conductor core (42, 62, 82, 102) has at least sectionally over the length of the flat conductor (40, 60, 80, 100) a partial area (52a-b, 70a-b, 114a-b) whose contour in the cross-section of the flat conductor core (42, 62, 82, 102) forms a straight line (46a-b, 54a-b, 72a-b, 116a-b),which extends over part of the height of the flat conductor core (42, 62, 82, 102), wherein the straight section (46a-b, 54a-b, 72a-b, 116a-b) extends over at least 75% of the height of the flat conductor core (42, 62, 82, 102). The invention further relates to an electrical flat conductor (40, 60, 80, 100) for motor vehicles with a flat conductor core (42, 62, 82, 102) made of electrically conductive flat conductor material and with insulation (44, 64, 84, 104) encasing the flat conductor core (42, 62, 82, 102) made of an insulating material, wherein the height (Hk) of the flat conductor core (42, 62, 82, 102) is less than the width (Bk) of the flat conductor core (42, 62, 82, 102) and wherein the insulation (44, 64, 84, 104) extends at least sectionally along the length of the flat conductor (40, 60, 80, 100) on at least one side (46a-b, 48a-b, 68a-b, 86a-b, 88a-b, 106a-b, 108a-b) of the flat conductor core (42, 62, 82, 102) has a greater wall thickness than on at least one other side (46a-b, 48a-b, 68a-b, 86a-b,88a-b, 106a-b, 108a-b) of the flat conductor core (42, 62, 82, 102).,