Motor Vehicle Conductor Track Unit with Embedded Insulation
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Solution Overview
Problem
Conductor track units in motor vehicles face challenges in withstanding harsh environmental conditions such as temperature, humidity, dirt, mechanical shocks, and vibrations, as existing solutions do not adequately address these issues.
Innovation Solution
The conductor track unit features conductor tracks embedded in an electrically insulating material with externally accessible electrical connections, where the conductor tracks are made of durable materials like steel or tinplate, and the connections are made of brass or copper with a gold coating, ensuring robustness and reliability while being independently producible and embedded within the insulating material for enhanced protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conductor tracks are made accessible from outside for electrical contacting, then ease of connection is improved, but corrosion protection and mechanical stability deteriorate
Solution Approach 1:
The conductor track unit is segmented into conductor tracks made of steel or tinplate and separate electrical connections made of corrosion-resistant materials like brass, copper, or aluminum. This segmentation allows each component to be optimized for its specific function: conductor tracks for mechanical stability and electrical connections for corrosion resistance and ease of connection.
Solution Approach 2:
The electrical connections are extracted as separate components from the conductor tracks and are accessible from the outside through openings in the insulating material. This extraction allows the electrical connections to be made from materials particularly well-suited for corrosion resistance while the conductor tracks can be made from materials optimized for mechanical stability.
2Reliability
If conductor tracks are made from corrosion-resistant materials, then corrosion protection is improved, but mechanical stability deteriorates
Solution Approach 1:
The conductor track unit divides the electrical conduction function into two separate components: conductor tracks made of steel or tinplate for mechanical stability, and separate electrical connections made of corrosion-resistant materials such as brass, copper, or aluminum. This segmentation resolves the contradiction by allowing each material to be optimized for its primary requirement.
Solution Approach 2:
Different materials are used in different locations within the conductor track unit based on local requirements: steel or tinplate for conductor tracks where mechanical stability is critical, and corrosion-resistant materials like brass, copper, or aluminum for electrical connections where corrosion resistance is paramount. The insulating material provides additional local protection where needed.
3Reliability
If conductor tracks are embedded in insulating material, then corrosion protection is improved, but manufacturing complexity increases
Solution Approach 1:
The conductor tracks and electrical connections are merged into a single integrated conductor track unit with a common insulating material housing. This merging provides uniform corrosion protection for all electrical components while maintaining relatively simple manufacturing processes. The insulating material encapsulates both conductor tracks and electrical connections, protecting them from corrosion without requiring complex separate manufacturing steps.
Data Source
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AI summary
The invention relates to a conductor track unit, in particular for a motor vehicle. The conductor track unit is provided with conductor tracks which are embedded in an electrically insulating material. The conductor tracks are, in particular completely, surrounded by the electrically insulating material and are therefore not accessible from the outside. Electrical connections are electrically connected to the conductor tracks. The electrical connections are accessible from the outside, and therefore can be electrically connected to electrical contacts of electrical or electronic components such as a switch, detector, electronic radio component, integrated circuit, electronic chip, electronic control device or motor, for example by soldering. The conductor tracks and electrical connections are different components which are therefore initially independent of one another and can be produced independently of one another. A particularly robust yet delicate conductor track unit can be provided in this way.