Layered Vehicle Electrical Interconnection for Multi-Voltage Packaging

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Solution Overview

Problem

Existing technologies face challenges in managing complex electrical systems in vehicles, particularly in electrified vehicles, where existing systems are cumbersome and inefficient, leading to increased vehicle costs and installation difficulties.

Innovation Solution

A modular electrical system for electrified vehicles is proposed, comprising distinct sub-systems for propulsion, power distribution, and vehicle zones, utilizing robotic installation methods and flexible, contoured conductors to simplify installation and reduce complexity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional electrical systems with multiple separate electrical systems operating at different voltages are used, then the electrical system can meet the power requirements of different components, but the system complexity increases and installation becomes difficult

Engineering Contradiction:

Improvepower requirements of different componentsVSAvoidsystem complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The electrical system is divided into multiple electrical systems operating at different voltages, with each system dedicated to specific voltage requirements. This segmentation allows different components to operate at their optimal voltages while maintaining clear separation between systems, reducing overall complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces a vertical stacking dimension by arranging electrical systems at different heights above the vehicle base. Multiple electrical systems are positioned at different vertical levels, allowing them to be organized by voltage level and function while utilizing the vertical space within the vehicle.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Adaptability or versatility

Engineering Contradiction:

Improvepower requirements of different componentsVSAvoidinstallation difficulty

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The electrical systems are pre-configured and pre-assembled in their final positions above the vehicle base before vehicle assembly. This preliminary arrangement allows for optimized cable routing and connection points to be established in advance, reducing installation complexity during final assembly.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

By organizing electrical systems vertically at different heights above the base, the patent creates a structured layered architecture that simplifies installation. Each layer can be independently assembled and then stacked, reducing the complexity of wire routing and connection management.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Adaptability or versatility

Engineering Contradiction:

Improvepower requirements of different componentsVSAvoidvehicle cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent employs universal connection interfaces and standardized mounting structures that can accommodate different voltage levels and system types. This universality allows the same basic framework and connection protocols to be used across all electrical systems, reducing development and manufacturing costs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The vertical stacking arrangement allows multiple electrical systems to share common mounting structures, support frameworks, and routing channels. By organizing systems vertically, the patent reduces the overall footprint and allows shared infrastructure components, lowering material and manufacturing costs.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Adaptability or versatility

Engineering Contradiction:

Improvepower requirements of different componentsVSAvoidvehicle packaging availability

Core Design Contradiction:

Adaptability or versatilityVSVolume of moving object

Solution Approach 1:

The patent utilizes the vertical dimension above the vehicle base to accommodate multiple electrical systems. By stacking electrical systems at different heights rather than spreading them horizontally, the invention maximizes the use of vertical space, leaving more horizontal volume available for other vehicle components and packaging.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentEP3815985B1Vehicle electrical interconnection system

Publication Date: 2026.01.07 APTIV TECHNOLOGIES LTD

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AI summary

Electrified vehicle electrical systems and formatting methods include arranging a first layer including one or more first electrical transmission lines each configured to carry electrical power at a first voltage to one or more electrical powertrain components of the electrified vehicle, arranging a second layer above at least a portion of the first electrical connection layer, wherein the second layer includes one or more second electrical transmission lines each configured to carry electrical power at a second voltage to one or more electrical power distribution components of the electrified vehicle, and arranging a third layer above at least a portion of the first and second layers, wherein the third layer includes one or more third electrical transmission lines each configured to carry electrical power at a third voltage to one or more input/output device components of the electrified vehicle.