Vehicle Wiring Module Segmented Conductor Plates Weight Reduction
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Solution Overview
Problem
Existing vehicle wiring systems face inefficiencies due to oversized metal wires, which increase weight and reduce fuel efficiency, as they are designed to match the sum of maximum current values rather than actual current requirements.
Innovation Solution
A vehicle-mounted wiring module with multiple conductor plates of varying cross-sectional areas and thicknesses, connected via coupling members with overcurrent protection, allowing for optimized current routing and reduced weight by matching wire size to specific current demands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sizes of the metal wires are designed to match the sum of the maximum values of the currents, then the power supply capacity is sufficient, but the cross-sectional areas of the wires are unduly increased, thus increasing the overall weight of the wires
Solution Approach 1:
The patent divides the single thick metal wire into multiple conductor plates with different cross-sectional areas. Each conductor plate is sized according to the specific current requirements of the electric device it serves, rather than all wires being sized for the maximum possible current. This segmentation allows the wiring system to provide sufficient power capacity while significantly reducing the total weight by using smaller conductors where less current is needed.
Solution Approach 2:
The patent applies local quality by making each conductor plate have a cross-sectional area specifically matched to the current requirements of its designated electric device. Instead of uniform wire sizing throughout the vehicle, each location receives a conductor with the appropriate local quality (cross-sectional area) for its specific power needs, optimizing both reliability and weight.
2Reliability
If the sizes of the wires are designed to match the sum of the maximum values of the currents, then the power supply capacity is sufficient, but the larger the weight of the objects installed on the vehicle, the poorer the fuel efficiency is
Solution Approach 1:
By segmenting the wiring system into multiple conductor plates of varying sizes, the patent reduces the total weight of the wiring harness. This weight reduction directly improves fuel efficiency while maintaining sufficient power supply capacity through the strategic distribution of current loads across appropriately sized conductors.
Solution Approach 2:
The local quality principle is applied by matching each conductor plate's cross-sectional area to the specific current demands of its served electric device. This localized optimization ensures that no excess weight is carried throughout the vehicle, thereby improving overall fuel efficiency while maintaining reliable power delivery to each device.
3Reliability
If the sizes of the wires are designed to match the sum of the maximum values of the currents, then the power supply capacity is sufficient, but the wires become heavy, thus reducing the fuel efficiency
Solution Approach 1:
The patent segments the monolithic thick wire design into a hierarchy of conductor plates with progressively smaller cross-sectional areas. This segmentation enables the system to maintain adequate power supply capacity through the collective capability of multiple conductors while dramatically reducing the total weight compared to using a single oversized wire.
Solution Approach 2:
Each conductor plate is given the local quality (cross-sectional area) precisely matched to the current requirements of its target electric device. This eliminates the waste of having uniformly heavy wires throughout the vehicle, reducing overall wire weight while preserving sufficient power capacity where needed.
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 enables appropriate current flow without excessive wire weight, improving fuel efficiency and reducing material costs by routing wires according to specific power requirements, thus minimizing the overall weight of the wiring module.
Implementation Method 1
The first coupling member includes a conductive first overcurrent protection portion. The first overcurrent protection portion is interposed between the first conductor plate and the second conductor plate, and is rendered non-conductive by a current that exceeds a first allowable current flowing therethrough.
Data Source
AI summary
Provided is a wiring module with a reduced weight. The wiring module is a vehicle-mounted wiring module that includes a conductor plate formed from a conductor that supplies power from an electricity storage device to an electric device. The wiring module includes a flat, conductive first conductor plate, a flat, conductive second conductor plate, and a conductive first coupling member. The first conductor plate has a first cross-sectional area. The second conductor plate has a second cross-sectional area smaller than the first cross-sectional area is, and is to be connected to the first conductor plate. The first coupling member couples the first conductor plate and the second conductor plate to each other.