Transitional Cross Section Power Cable for Confined EV Routing
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Solution Overview
Problem
Existing electrical bus bars are inefficient for applications requiring tight spaces due to the skin effect, especially at high frequencies, and traditional round conductors cannot fit in confined areas like electric vehicle undercarriages or passenger compartments.
Innovation Solution
A multi-strand electrical cable that transitions from a circular or oval cross-section to a flattened square or rectangular section, achieved by untwisting and flattening the strands under pressure, with a strain relief and insulator application to ensure durability and chemical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a traditional round conductor is used, then the electrical connection is simple and reliable, but it cannot fit in confined spaces such as electric vehicle undercarriages or passenger compartments
Solution Approach 1:
The conductor is divided into multiple individual strands rather than a single solid conductor. These strands can be independently arranged and configured to achieve both round and flat cross-sectional shapes in different sections, enabling the conductor to adapt to confined spaces while maintaining electrical connectivity
Solution Approach 2:
The conductor transitions from a traditional round cross-section to a flat cross-section by changing the dimensional arrangement of the strands. The flat section is achieved by spacing the strands apart in a planar configuration, reducing the vertical profile to fit in confined spaces such as electric vehicle undercarriages
2Shape
If the conductor strands are spaced apart to form a flat section, then it can fit in confined spaces, but the strands may shift or separate compromising structural integrity
Solution Approach 1:
A flexible conduit or sheath is introduced as an intermediary element that encloses the spaced-apart strands. This conduit maintains the flat cross-sectional shape while preventing the strands from shifting or separating, ensuring structural integrity and reliability in confined space applications
Solution Approach 2:
A flexible protective sheath or coating is applied to the conductor assembly. This flexible shell maintains the flat configuration of the spaced strands while providing mechanical support and preventing strand separation, ensuring the conductor remains reliable during installation and operation
Data Source
AI summary
An electrical cable is provided with a rounded insulated electrical conductor that transitions to a flattened section to fit into areas where the rounded portion does not fit. A round electrical conductor transitions to a flattened section for electrical conduction routing via the undercarriage of a vehicle, for routing under the carpeting of the passenger compartment, or other confined spaces. The electrical cable may illustratively be used in an electric car application where distribution of electrical current from the battery compartment to the motor requires additional wiring in the vehicle not found in combustion based engines. The reduced vertical profile of the flattened section provides for additional clearance between the vehicle undercarriage and the road, or between the undercarriage frame and the interior passenger compartment carpet.