Thermal Circuit Breaker Integrated into Vehicle Power Supply Cable
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Solution Overview
Problem
Current thermally actuated circuit breakers for vehicle power supplies are cumbersome and weight-intensive, requiring extensive cable routing and separate mechanical and electrical fixation, which increases vehicle weight and costs, and are not easily integratable into the onboard electrical system.
Innovation Solution
A thermally actuated circuit breaker with a temperature-dependent switching mechanism and bimetal element, using a PTC resistor as a heating element, is designed with external terminals that can be integrated directly into a vehicle power supply cable, featuring screwless connections such as insulation displacement contacts or crimp connections, allowing for self-resetting operation and reduced overheating risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If circuit breakers are inserted in sockets of onboard electronics with separate mechanical and electrical fixation, then reliable overcurrent protection is achieved, but vehicle weight and installation complexity increase
Solution Approach 1:
The circuit breaker is integrated directly into the cable harness, merging the previously separate components (circuit breaker, mechanical fixation, and electrical connection) into a single unified structure. This eliminates the need for separate sockets and fixation elements, reducing overall weight while maintaining protection functionality
Solution Approach 2:
The integrated circuit breaker serves multiple functions simultaneously: it provides overcurrent protection, mechanical anchoring to the cable harness, and electrical connection points all in one component. This multi-functionality eliminates the need for separate dedicated sockets and fixation mechanisms
2Reliability
If circuit breakers are inserted in sockets of onboard electronics with separate mechanical and electrical fixation, then reliable overcurrent protection is achieved, but device complexity and installation effort increase
Solution Approach 1:
The circuit breaker is integrated directly into the cable harness, merging the previously separate components (circuit breaker, mechanical fixation, and electrical connection) into a single unified structure. This eliminates the need for separate sockets and fixation elements, reducing overall weight while maintaining protection functionality
Solution Approach 2:
The integrated circuit breaker serves multiple functions simultaneously: it provides overcurrent protection, mechanical anchoring to the cable harness, and electrical connection points all in one component. This multi-functionality eliminates the need for separate dedicated sockets and fixation mechanisms
3Reliability
If extensive cable routing is used to connect loads to onboard electronics, then electrical connection is achieved, but vehicle weight and costs increase
Solution Approach 1:
The cable system is segmented into multiple independent zones, each with its own integrated circuit breaker. This allows cable routing to be optimized locally for each segment rather than requiring all loads to connect to a central onboard electronics unit, reducing overall cable length and weight
Solution Approach 2:
The circuit breaker integration transforms the cable harness from a passive connection medium into an active protective system distributed throughout the vehicle. By placing protection functions directly in the cable segments rather than centralizing them, the system distributes functionality across multiple spatial dimensions
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
The solution enables a compact, lightweight, and cost-effective integration of the circuit breaker into vehicle power supply cables, reducing weight and installation complexity while maintaining reliable overcurrent protection and self-resetting capabilities.
Implementation Method 1
a heating element in the form of a PTC resistor, which rests on the bimetal element and is supported by means of a spring element on a fixed contact arm
Implementation Method 2
a temperature-dependent switching mechanism, which subject to its temperature establishes an electrically conductive connection between two external terminals
Data Source
AI summary
A thermally activated safety switch for safeguarding a consumer of a power supply network of a vehicle, having a switch housing in a temperature-independent switching unit, which subject to the temperature thereof establishes an electrically conductive connection between two external terminals fed out of the switch housing, wherein the external terminals are fed out at opposite housing sides of the switch housing. On the one hand, the external terminals are provided for an electrical and mechanical terminal connection to the cable connection ends of a consumer to be protected, and on the other hand to a cable portion leading to an on-board power supply electronics, and are configured accordingly.