Motor Vehicle Body Part Embedding Electrical Lines
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Solution Overview
Problem
In vehicles with electric drive, the integration of thick and heavy electrical line elements complicates structural space management due to non-adjacent high-voltage batteries and electric motors, requiring complex insulation and limiting design freedom.
Innovation Solution
A body part arrangement with a molded plastics part embedding electrical line elements, using thermoplastic materials for insulation and increased rigidity, potentially with fiber reinforcement, and a hybrid component design combining metallic and plastic materials, allowing for simplified production and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electrical line elements are integrated into body parts using integral lamination, then body parts can be easily utilized as channels for electrical line elements, but separate electrical insulation of the electrical line elements is imperatively necessary, making the production method complex and restrictive with regard to design freedom
Solution Approach 1:
The patent merges the structural function and insulation function into a single integrated body part. The receiving material serves both as the structural component and as the electrical insulation medium, eliminating the need for separate insulation layers. This integration resolves the technical contradiction by simplifying the production method while maintaining ease of manufacture.
Solution Approach 2:
The receiving material performs multiple functions simultaneously: it provides structural support as a body part and provides electrical insulation for the integrated line elements. This multi-functionality eliminates the need for separate insulation components, thereby reducing production complexity while maintaining ease of manufacture.
2Power
If thick and heavy electrical line elements are installed in the motor vehicle, then high electrical currents can flow between high-voltage battery and electric motor, but structural space situation is complicated
Solution Approach 1:
The electrical line elements are nested within the receiving material of the body part, similar to a nested doll structure. This integration allows thick line elements capable of handling high currents to be housed within the existing body part structure, thereby maintaining power capacity while minimizing additional space requirements.
Solution Approach 2:
Instead of routing line elements through separate body channels that consume lateral space, the patent integrates them within the receiving material in a different spatial arrangement. This dimensional reorganization allows high-current line elements to be accommodated within the existing body part volume, reducing the overall structural space requirement.
3Reliability
If separate electrical insulation is provided for electrical line elements, then electrical safety is ensured, but design freedom is restricted
Solution Approach 1:
The insulation function is merged with the structural body part itself. The receiving material is designed to provide both mechanical support and electrical insulation in a unified component, ensuring electrical safety while granting complete design freedom for shaping and configuring the body part according to specific application requirements.
Solution Approach 2:
The patent utilizes the electrical and mechanical properties of the receiving material by changing its parameter characteristics. By selecting materials with appropriate dielectric properties and mechanical strength, the receiving material simultaneously provides insulation and structural support, ensuring reliability while allowing versatile design configurations.
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
This approach simplifies the integration of electrical line elements, eliminates the need for separate insulation, enhances design freedom, and increases the structural rigidity of the body part while minimizing space requirements.
Implementation Method 1
The plastics part is produced from a thermoplastic material, whereby the electrical line element is electrically insulated in a simple manner
Implementation Method 2
the thermoplastic material is of fiber-reinforced, preferably glass-fiber-reinforced, design
Data Source
AI summary
A body part arrangement for a motor vehicle includes a body part in which at least one electrical line element is integrated in a receiving material of the body part. The body part includes a molded part in which a plastics part is provided. The at least one electrical line element is embedded in the plastics part.