Trailer Wiring Over-Current Protection with Reduced Copper
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Solution Overview
Problem
In vehicle trailer lighting systems, the use of smaller copper conductors to reduce copper usage leads to increased resistance and potential short circuit issues, as the reduced conductor size may not trip the 25 amp breaker, potentially causing wiring insulation to melt, and results in less rigid and harder-to-install wiring, increasing labor costs.
Innovation Solution
An electrical power supply device with a plurality of electrically conductive wires, including those smaller than 14 gauge copper, non-copper materials, copper alloys, or copper sheaths, integrated with an over-current protection device that breaks current flow below 25 amperes, ensuring safe operation and mechanical stiffness through additional insulation and stiffeners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If smaller diameter copper conductors are used to reduce copper usage, then copper cost is reduced, but the resistance increases and may not trip the 25 amp breaker during short circuit conditions
Solution Approach 1:
The patent changes the amperage threshold parameter of the over-current protection device from the conventional 25 amps to a lower value (1-12 amps) that matches the reduced current capacity of smaller conductors. This allows the protection system to operate effectively with reduced copper usage while maintaining safety.
Solution Approach 2:
The patent introduces an intermediary over-current protection device with a lower amperage threshold that acts as a mediator between the smaller conductors and the existing 25 amp breaker. This intermediary device trips before the breaker, preventing harmful effects while allowing copper reduction.
2Quantity of substance
If smaller diameter copper conductors are used, then copper cost is reduced, but the wiring becomes less rigid and harder to install
Solution Approach 1:
The patent employs composite construction for the conductor assembly, combining smaller copper conductors with non-conductive stiffening elements. This composite structure reduces copper usage while maintaining the mechanical rigidity needed for easy installation during manufacturing.
3Reliability
If lower amperage threshold over-current protection is used, then short circuit protection is improved for smaller conductors, but the device complexity increases
Solution Approach 1:
The patent employs a simple, inexpensive over-current protection device with a lower amperage threshold that can be easily integrated into the existing breaker system. The device uses basic protective components that are cost-effective and simple in design, minimizing the increase in overall system complexity.
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 effectively reduces copper usage while ensuring safe operation by preventing overheating and maintaining mechanical integrity, addressing the challenges of reduced conductor size and rigidity, thus lowering costs and improving installation efficiency.
Implementation Method 1
a short that occurs 50 feet from the trailer nose box would draw 18 amps, high enough to potentially melt the wiring insulation, but below the 25 amps required to trip the typical breaker in the tractor
Data Source
AI summary
An electrical power supply device for a trailer lighting system behind a truck is disclosed. The trailer lighting system including at least two FMVSS 108 compliant LED stop-tail-turn lamps. The electrical power supply device has an outer casing including a terminal to be electrically attached to and become part of the trailer lighting system. There are a plurality of electrically conductive wires within the casing. At least one of the wires is selected from one or more of the group consisting of low copper usage wire. The device has an over-current protection device along at least one which breaks current flow through the one wire below at an amperage threshold less than 25 amperes.