Modular Flat Battery Lead for Complex Installation Spaces
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Solution Overview
Problem
Conventional motor vehicle battery leads, particularly B+ leads, face challenges in meeting complex installation space requirements due to their circular shape, which necessitates narrow bending radii and long lengths, leading to production difficulties and logistical complexities, especially when multiple vehicle versions require different cable lengths.
Innovation Solution
The battery lead is designed as a modular flat conductor composed of multiple parts, allowing for flexible connection and bending in various planes to adapt to specific installation spaces, with parts connected using positive and/or non-positive fits, and potentially welded together, enabling efficient production and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If flat conductors are used to reduce installation space requirements, then the conductor cross section can be widened to guarantee current load-carrying capacity, but the conductors become unwieldy when narrow bending radii are necessary
Solution Approach 1:
The flat conductor is divided into multiple sections that can be independently bent and connected. This segmentation allows each section to be formed with appropriate bending radii while maintaining the overall flat conductor structure, resolving the conflict between wide cross-section requirements and narrow bending radius needs.
Solution Approach 2:
The conductor is designed to bend in multiple spatial dimensions by connecting flat sections at different orientations. This allows the conductor to navigate complex installation paths with narrow radii while maintaining its flat wide cross-section for adequate current carrying capacity.
2Adaptability or versatility
If battery leads are made as long as several metres to reach from boot to engine compartment, then installation flexibility is improved, but logistics and stock control become complex and costly
Solution Approach 1:
The long battery lead is segmented into multiple shorter flat conductor sections that can be produced, stored, and transported more easily. These sections are assembled on-demand to create the required length and configuration, reducing logistics complexity while maintaining installation flexibility.
Solution Approach 2:
The battery lead system becomes dynamic and configurable, allowing different lengths and configurations to be assembled from standardized sections based on specific vehicle requirements. This eliminates the need to maintain complex inventories of pre-formed long leads in various configurations.
3Adaptability or versatility
If flat conductors are bent in all three spatial directions to meet installation space requirements, then adaptability to installation space is improved, but production difficulty increases due to narrow radii requirements
Solution Approach 1:
By dividing the conductor into separate sections, each section can be bent in controlled directions with standardized radii. This segmentation transforms the complex task of bending a single long conductor in three dimensions into simpler, more precise operations on individual sections that can be performed with standard tooling.
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
This modular design simplifies production and logistics by allowing individual parts to be customized and assembled just before use, reducing production complexity and transport costs while accommodating diverse installation space requirements with precise bends and angles.
Implementation Method 1
The parts of the flat conductor are connected to one another in each case with a positive and/or non-positive fit and/or with a material fit
Data Source
AI summary
Motor vehicle battery lead with a first connection element for a battery pole, a second connection element for at least one consumer, and a flat conductor arranged between the first connection element and the second connection element. A modular construction with a high degree of flexibility is achieved, in that the flat conductor is formed in a number of parts, wherein at least two parts of the multi-part flat conductor are connected to each other over the course of the flat conductor.