Vehicle Battery Cable With Segmented Strands

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Solution Overview

Problem

Conventional motor vehicle battery cables experience increased contact resistance and susceptibility to corrosion due to multiple connections, leading to electrical losses and faults in the vehicle's electrical system.

Innovation Solution

A motor vehicle battery cable composed of multiple strands of wire with varying cross-sections, routed together in an insulating layer, allowing for adaptable current-carrying capacity and reduced contact points, minimizing electrical resistance and corrosion risk.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple connections and transitions are used in conventional battery cable systems, then adaptability to different consumers and generators is improved, but contact resistance and electrical losses increase

Engineering Contradiction:

Improveadaptability to different consumersVSAvoidelectrical losses

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The cable is divided into multiple individual strands of wire with different cross-sections, each capable of being connected to different consumers or generators. This segmentation allows the cable system to adapt to various electrical loads while maintaining fewer connection points, as multiple strands can be bundled together to form a single cable assembly with reduced contact resistance.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If multiple connection points and transitions are used, then versatility in connecting different electrical components is improved, but susceptibility to corrosion and faults increases

Engineering Contradiction:

Improveversatility in connecting componentsVSAvoidsusceptibility to corrosion

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

Multiple strands of wire are combined into a single cable assembly with a common insulating layer and connection structure. This merging reduces the number of external connection points and transitions exposed to environmental factors, thereby decreasing susceptibility to corrosion and faults while maintaining the ability to connect to various electrical components through the bundled strands.

Inventive Principle:

Principle #5Merging (Combining)

3Power

If a large line cross-section is used throughout the entire cable, then current-carrying capacity is improved, but cable weight increases

Engineering Contradiction:

Improvecurrent-carrying capacityVSAvoidcable weight

Core Design Contradiction:

PowerVSWeight of moving object

Solution Approach 1:

Different strands within the cable assembly have different cross-sections optimized for their specific functions and positions. Strands closer to the battery or serving high-current applications have larger cross-sections, while strands for lower-current consumers have smaller cross-sections. This local optimization maintains adequate current-carrying capacity where needed while reducing overall cable weight.

Inventive Principle:

Principle #3Local quality

Data Source

PatentEP2899075B1Vehicle battery cable

Publication Date: 2018.01.03 AUTO KABEL MANAGEMENT GMBH

Figure 1~2
Figure 3~3c

AI summary

To reduce line resistance and susceptibility to interference, a motor vehicle battery cable (21) is provided with a conductor formed from individual conductor strands (22, 26, 28). The conductor strands (22, 26, 28) are guided within a common insulating layer (29) and are individually led out of the insulating layer at various points.