Prefabricated Cable-Connector Assembly for Low-Resistance HV Contacts
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Solution Overview
Problem
High-voltage electrical connectors in the automotive industry face challenges in achieving low contact resistance, mechanical robustness, and cost-effective production, particularly in high-power applications where thermal loads are significant, and existing solutions like welded contact blades or compacted stranded wires are complex and prone to uneven contact surfaces.
Innovation Solution
An assembled electrical cable with a stranded conductor compacted into a plate-shaped end section, combined with a contact element, such as a contact plate, which provides a large contacting area and precise surface quality, reducing contact resistance and allowing for high-current transmission while being economical and suitable for mass production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a welded contact blade is used to connect the electrical conductor to the connector, then the mechanical connection strength is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The invention extracts the contact blade from the connector assembly and integrates it directly into the cable assembly during manufacturing. The contact blade is pre-attached to the electrical conductor in a controlled manufacturing environment, separating the connection preparation from the final connector assembly process. This reduces on-site manufacturing complexity while maintaining connection strength.
Solution Approach 2:
The contact blade is pre-attached to the electrical conductor before the cable is installed in the connector. This preliminary action allows the connection to be prepared in advance under controlled conditions, simplifying the final assembly process and reducing manufacturing complexity at the installation site.
2Ease of manufacture
If the electrical conductor is compacted in a plate-like manner to serve as a contact element, then the manufacturing process is simplified, but the contact surface uniformity deteriorates
Solution Approach 1:
The invention introduces a contact blade as an intermediary element between the compacted electrical conductor and the mating contact element. The contact blade provides a standardized, uniform contact surface that compensates for the non-uniformity of the compacted stranded wire, ensuring reliable electrical contact while maintaining the simplicity of compacting the conductor.
Solution Approach 2:
The invention applies different properties to different parts of the connection system. The electrical conductor is compacted for mechanical stability and ease of manufacture, while the contact blade provides a locally optimized uniform contact surface for reliable electrical contact. Each component has its own optimized characteristics suited to its specific function.
3Loss of energy
If the contact resistance is reduced to minimize heat loss, then the energy efficiency is improved, but the manufacturing complexity increases
Solution Approach 1:
The invention merges the electrical conductor and contact blade into a single pre-assembled unit during cable manufacturing. This integration ensures optimal electrical contact between the conductor and contact blade, minimizing contact resistance and heat loss. The merged structure is manufactured in a controlled environment, avoiding the need for complex field assembly procedures.
4Reliability
If a separate contact blade is attached to the electrical conductor, then the electrical connection quality is improved, but the assembly complexity increases
Solution Approach 1:
The contact blade is pre-attached to the electrical conductor during cable manufacturing before the cable is installed in the connector. This preliminary action ensures high-quality electrical connection is achieved in advance under controlled manufacturing conditions, simplifying the final connector assembly process and reducing field assembly complexity.
Data Source
Figure 1~4
Figure 5~9
Figure 10~12
AI summary
The invention relates to a pre-assembled electrical cable (2) for an electrical connector (3), comprising an electrical conductor (8) designed as a stranded wire consisting of several individual wires, and having at least one plate-shaped compacted end section (10). The pre-assembled electrical cable (2) is provided to have an elongated contact element (11) with at least one side surface forming a first connecting surface (12) connected to the compacted end section (10) of the electrical conductor (8), and with at least one further side surface facing away from the first connecting surface (12) forming a first contact surface (13) for contacting a mating contact surface (14) of a mating contact element (7) of a mating connector (5).