Plate-Like Cable Assembly for Compact Multi-Cable Connections
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Solution Overview
Problem
Existing cable connection methods, particularly in the automotive industry, are costly and require complex connectors that are large, heavy, and expensive due to the need for separate carrier plates, which are often made of copper, and do not adequately address mechanical and thermal stress.
Innovation Solution
The electrical conductors of at least one cable are designed as a carrier plate to connect multiple cables without a separate carrier plate, using stranded wires that are compacted or packaged to form a flat surface for easy and reliable electrical and mechanical connections, eliminating the need for additional components and reducing material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate copper carrier plates are used to connect multiple electrical cables, then reliable electrical and mechanical connections are achieved, but manufacturing costs and material costs increase significantly
Solution Approach 1:
The patent merges the carrier plate function with the electrical conductor itself. The electrical conductor is formed in a plate-like manner directly, eliminating the need for a separate copper carrier plate. This integration maintains connection reliability while significantly reducing material costs and manufacturing complexity.
Solution Approach 2:
The electrical conductor serves multiple functions: it acts as both the electrical conductor and the carrier plate for connecting multiple cables. This multi-functionality reduces the number of components needed and simplifies the overall connection structure.
2Reliability
If complex connectors are used to connect high-voltage electrical cables, then connection security and robustness are improved, but the connectors become large, heavy, and expensive
Solution Approach 1:
The connector components are merged into a single integrated plate-like electrical conductor structure. This eliminates the need for separate connector housings, carrier plates, and fastening components, significantly reducing weight while maintaining connection security through the robust plate-like design.
Solution Approach 2:
The patent extracts the essential connection function from complex connector assemblies and implements it through a simplified plate-like electrical conductor structure. Only the necessary electrical conduction and mechanical connection features are retained, removing unnecessary weight.
3Reliability
If separate copper carrier plates are used for cable connections, then reliable electrical connections are achieved, but the overall cable arrangement size increases
Solution Approach 1:
The carrier plate and electrical conductor are merged into a single plate-like structure. This integration eliminates the space required for separate components and their associated mounting structures, reducing the overall volume of the cable arrangement while maintaining reliable electrical connections.
4Reliability
If multiple separate components are used to connect electrical cables, then connection robustness is achieved, but assembly complexity and time increase
Solution Approach 1:
Multiple separate components (carrier plate, electrical conductor, fasteners) are merged into a single plate-like electrical conductor structure. This integration reduces the number of assembly steps and fastening operations required, significantly improving assembly speed while maintaining connection robustness through the integrated design.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a cable assembly (2) comprising at least three electric cables (3, 7) which have electric conductors (5) that are electrically and mechanically connected together. Each of the electric conductors (5) is free of an insulation material (6) and is plate-shaped in a contact point (9). One of the cables (3, 7) is designed as a support cable (7), and the electric conductor (5) of the support cable (7) is formed as a support plate (4) at the contact point (9) in order to attach the contact points (9) of the other electric conductors (5). Multiple contact points (9) of the other electric conductors (5) are secured to a surface (8) of the support plate (4) next to one another.