Articulating Cable Covers for Uneven Surface Power Routing

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Solution Overview

Problem

The deployment of power systems, such as photovoltaic and electric vehicle charger systems, on uneven surfaces is costly and inefficient due to the need for grading and trenching, which increases installation costs and exposes cables to environmental risks.

Innovation Solution

A cable management system (CMS) that contours to uneven surfaces, allowing vehicular traffic and featuring articulating joints and drive-over designs to eliminate the need for grading and trenching, while protecting cables from exposure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If cables are routed above-ground on uneven surfaces, then deployment costs are reduced, but cables are exposed to environmental elements and vehicular traffic

Engineering Contradiction:

Improvedeployment costVSAvoidcable exposure to environmental elements and traffic

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent employs a flexible cable management system composed of interlocking segments that can be laid over uneven surfaces without requiring trenching or grading. These segments act as protective shells that shield cables from environmental elements and vehicular traffic while maintaining above-ground routing, thus reducing deployment costs compared to traditional trenching methods.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The cable management system is divided into multiple modular segments that can be easily assembled and configured to fit uneven terrain. This segmentation allows the system to adapt to various surface conditions while providing continuous protection for cables, eliminating the need for expensive civil work associated with traditional underground routing.

Inventive Principle:

Principle #1Segmentation

2Object-affected harmful factors

If traditional trenching and grading are performed, then cables are protected from exposure, but deployment costs increase significantly

Engineering Contradiction:

Improvecable protection from exposureVSAvoiddeployment cost

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

Instead of burying cables underground through trenching and grading to protect them, this patent inverts the approach by placing cables above-ground and protecting them with a flexible cable management system. This reversal eliminates the need for expensive civil work while still providing adequate protection from environmental elements and traffic.

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of operation

If the installation surface is graded, then cables can be routed properly, but deployment costs and installation time increase

Engineering Contradiction:

Improvecable routing capabilityVSAvoidinstallation time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The cable management system is designed to be dynamic and adaptable to uneven surfaces rather than requiring the surface to be modified. The flexible segments can conform to various terrain conditions, eliminating the time-consuming grading process while ensuring proper cable routing and protection.

Inventive Principle:

Principle #15Dynamics

4Object-affected harmful factors

If metal plates are installed to protect cables, then cables are protected from traffic, but deployment costs increase

Engineering Contradiction:

Improvecable protection from vehicular trafficVSAvoiddeployment cost

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent replaces rigid metal plates with flexible cable management segments that provide equivalent protection from vehicular traffic. These flexible segments are easier to install on uneven surfaces and reduce deployment costs compared to heavy metal plates, while still providing adequate shielding for the cables.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS20240380195A1Cable management systems

Publication Date: 2024.11.14 SHOALS TECHNOLOGIES GROUP LLC

AI summary

A cable management system may include a first segment, a second segment, or a pivoting link. The first segment may define a first volume configured to receive a cable. The second segment may define a second volume configured to receive the cable. The pivoting link may be configured to couple to the first segment to prevent rotation of the first segment relative to the pivoting link. The pivoting link may also be configured to couple to the second segment to form an articulating joint configured to permit the second segment to rotate relative to the pivoting link.