Modular Insulation for Flat Conductors in Motor Vehicles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for insulating 3D-shaped flat cables in motor vehicles face challenges due to high mechanical loads, varying temperature requirements, and inefficient use of insulation materials, particularly with hard insulation materials and large cross-sections, which demand high-quality materials and complex extrusion processes.
Innovation Solution
A modular insulation system where insulation elements with adapted cross-sections and bending geometries are used to encase the flat conductor, allowing for selection based on specific bending angles and radii, and made from more rigid materials than conventional extruded insulation, enabling efficient insulation of flat conductors with varying geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single high-quality insulation material is used for the entire flat cable to meet maximum requirements (tight bending radii and high temperatures), then the insulation meets all requirements, but the material usage is inefficient and costs increase
Solution Approach 1:
The flat cable is divided into multiple sections along its longitudinal axis, with each section equipped with insulation elements that are specifically adapted to the local requirements (bending radius, temperature). This segmentation allows each insulation element to be optimized for its specific location rather than using a single high-quality material throughout the entire cable.
Solution Approach 2:
Different insulation elements with different material properties and geometries are applied to different sections of the flat cable based on local requirements. Sections requiring high temperature resistance use appropriate materials, while sections requiring tight bending radii use insulation elements with corresponding geometric adaptations, achieving local optimization rather than uniform high-quality insulation throughout.
2Strength
If hard insulation materials or large cross sections are used, then the insulation provides adequate protection, but large extruders and long cooling sections are required
Solution Approach 1:
The insulation is applied in separate modular elements rather than as a single continuous extrusion. This segmentation allows each insulation element to be produced with simpler extrusion equipment and shorter cooling sections, while still providing adequate protection when the elements are assembled along the flat cable.
Solution Approach 2:
The insulation system becomes dynamic and adaptable - different insulation elements can be selected and applied based on the specific requirements of each cable section. This modularity allows the system to provide adequate protection where needed without requiring complex extrusion equipment for all sections.
3Adaptability or versatility
If the flat cable is bent in at least two spatial directions to fit inside the motor vehicle, then the cable can be routed appropriately, but the mechanical load on the insulation material increases
Solution Approach 1:
The cable is divided into sections with insulation elements applied to each segment. This allows the flat cable to be bent in multiple spatial directions at specific locations while maintaining insulation integrity, as each insulation element can be designed to accommodate the local bending geometry.
Solution Approach 2:
Insulation elements with specific geometric adaptations are applied to sections requiring bending, while other sections may use simpler insulation. This local adaptation allows the cable to achieve the required routing flexibility without subjecting the entire insulation system to excessive mechanical loads.
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
A motor vehicle power supply kit includes a flat conductor (2) with a square profile and a plurality of insulating elements (8) which have a receptacle adapted to the profile of the flat conductor, wherein the insulating elements each have a smaller longitudinal extent than the flat conductor, wherein the flat conductor is sectionally sheathed with at least two insulating elements selected from the plurality of insulating elements.