Bistable EV Charging Cable Structure for Compact Stowage
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Solution Overview
Problem
Existing charging cables for electrified vehicles occupy valuable storage space and are difficult to handle due to mechanical tension and restoring forces, making them an obstacle during charging and stowage.
Innovation Solution
A charging cable with specified bending regions that can transition between stable bent and extended states, stabilized by bistable spring elements, allowing easy stowage and handling without constant mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If an elastic charging cable is stored in a helically wound form to save space, then the storage space is reduced, but the restoring forces hinder cable handling and the cable becomes an obstacle during use
Solution Approach 1:
The cable is divided into multiple segments with different properties: a flexible section for storage and handling, and a rigid section for stable positioning during use. This segmentation allows the cable to exhibit different behaviors in different operational states, resolving the contradiction between compact storage and easy handling.
Solution Approach 2:
The cable transitions from a static helical storage form to a dynamic extended form during use. The flexible section allows the cable to be easily manipulated and extended, while the rigid section provides stability when positioned, creating a dynamic system that adapts to operational requirements.
2Adaptability or versatility
If multiple charging cables for different modes are carried in the vehicle, then compatibility with different charging infrastructures is improved, but valuable storage space is occupied
Solution Approach 1:
The charging cable system is designed to perform multiple functions: the flexible section can be used for manual handling and extension, while the rigid section provides stable positioning. This multi-functionality allows a single cable design to serve multiple charging modes and infrastructures without requiring separate specialized cables, thereby maintaining versatility while reducing storage space requirements.
3Volume of moving object
If a helically wound elastic cable is used to reduce housing requirements, then space-saving is achieved, but mechanical tension makes the cable difficult to bring near the ground
Solution Approach 1:
By segmenting the cable into flexible and rigid sections, the mechanical tension problem is localized to the flexible section which is designed to accommodate coiling and winding. The rigid section is positioned away from the high-tension storage area, allowing the cable to be stored compactly while minimizing the impact of mechanical tension during ground-level operations.
Solution Approach 2:
Different sections of the cable are assigned different mechanical properties: the flexible section has high elasticity to accommodate storage tension, while the rigid section maintains structural integrity during use. This local differentiation of material properties allows the cable to withstand storage tension without compromising handling ease during operational phases.
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 cable achieves efficient storage and easy handling by defining a compact form for stowage, reducing space requirements and eliminating handling difficulties.
Implementation Method 1
The cable body (13) has a multiplicity of specified bending regions (14), each of which can assume either a first semi-rigid state, S, that is generally extended, straight, or linear, or a second semi-rigid state, B, that is generally curved, bent, or curvilinear
Implementation Method 2
each of which can assume either a first semi-rigid state, S, that is generally extended, straight, or linear, or a second semi-rigid state, B, that is generally curved, bent, or curvilinear, as a result of elastic deformation
Data Source
AI summary
Electrified vehicle charging equipment includes a charging cable having a cable body including insulated conductors surrounded by a sheath, the cable body including alternating first and second regions, the first regions containing a bistable resilient strip having a first extended stable state and a second curved stable state, the bistable resilient strip resisting an external force to move the first regions away from the first or second stable states and to move the first regions toward one of the first and second stable states when the first regions are not in the first or second stable states, a first plug connected to a first end of the cable body and configured to connect the plurality of insulated conductors to an electrified vehicle, and a second plug connected to a second end of the cable body and configured to connect the plurality of insulated conductors to a charging source.