Flexible Branch Conductor for Compact Electrical Conduction Path

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional electrical conduction paths for hybrid and electric automobiles have an increased diameter due to the terminal fitting fixed to the outer surface of the second conductor, which complicates the connection and increases the overall path diameter.

Innovation Solution

The electrical conduction path incorporates a flexible branch conductor that can be deformed into a compact elongated shape and an expanded tubular shape, with a fixing member that attaches to the outer surface of the second conductor, reducing the connection region's diameter and the path's overall diameter.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a terminal fitting with an open barrel-shaped crimp portion is used to connect the second conductor and the conductive member, then the connection is achieved, but the outer diameter of the connection region increases

Engineering Contradiction:

Improveconnection reliabilityVSAvoidouter diameter of connection region

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The branch conductor is inserted into the crimp portion of the terminal fitting, and the terminal fitting is then crimped to enclose the branch conductor. This nested structure allows the conductive member to be contained within the terminal fitting's crimp portion, preventing the outer diameter from increasing significantly while maintaining reliable electrical connection between the second conductor and the conductive member

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If the conductive member is fixed to the terminal fitting with an open barrel-shaped crimp portion, then the connection is established, but the overall diameter of the electrical conduction path increases

Engineering Contradiction:

Improveconnection stabilityVSAvoidoverall diameter of electrical conduction path

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The terminal fitting is crimped to enclose both the branch conductor and the conductive member in a nested arrangement. This allows the conductive member to be fixed securely to the terminal fitting while remaining contained within the terminal fitting's outer diameter, thus maintaining connection stability without increasing the overall diameter of the electrical conduction path

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

Instead of extending the connection structure radially outward (increasing diameter), the terminal fitting utilizes axial compression through crimping to achieve secure connection. This dimensional shift from radial expansion to axial compression allows reliable connection while maintaining a compact overall diameter

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS10916864B2Electrical conduction path

Publication Date: 2021.02.09 SUMITOMO WIRING SYSTEMS LTD

AI summary

An electrical conduction path that includes a first conductor; a tubular first insulator that encloses the first conductor; a tubular second conductor that encloses the first insulator, and has shape retainability; a branch conductor that is flexible so as to be deformable into a compact elongated shape and into an expanded tubular shape, the branch conductor deformed into the expanded tubular shape enclosing an outer circumferential surface of the second conductor; and a fixing member that fixes the branch conductor to the outer circumferential surface of the second conductor.