Breakaway Cable Bundle Router for Impact Pullout Protection
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Solution Overview
Problem
High voltage cables in vehicle systems are susceptible to high pullout forces during impact events, which can cause damage to electrical connectors.
Innovation Solution
A cable bundle router with a base plate and cable cover system that includes fastener clips designed to break away under a predetermined load, releasing the cables to prevent pullout forces during impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cable bundle router uses a secure fastening system to hold HV cables, then cable security is improved, but the cables become vulnerable to high pullout forces during impact events
Solution Approach 1:
The fastening system is segmented into multiple fastener clips distributed along the cable bundle router. Each fastener clip can independently break away under impact load, allowing the system to dissipate impact forces through sequential failure of individual segments rather than transmitting the full force to the cable connector.
Solution Approach 2:
The fastener clips are designed as sacrificial components that are intentionally made to break away under predetermined impact loads. These clips are replaceable parts that protect the more valuable cable connectors by sacrificing themselves during impact events, embodying the principle of using disposable components to protect permanent ones.
2Stability of the object's composition
If the cable bundle router provides rigid support for HV cables, then cable positioning is improved, but the cables cannot flex to absorb impact energy
Solution Approach 1:
The cable bundle router transitions from a static rigid support structure to a dynamic system where the fastener clips can change state from secured to broken. This dynamic behavior allows the system to adapt to impact events by enabling cable movement when needed while maintaining positioning stability during normal operation.
Solution Approach 2:
The system changes the mechanical property parameters of the fastening connection from high strength (during normal operation) to low strength (during impact). The fastener clips are designed with specific material properties and geometric features that allow them to break at predetermined loads, effectively changing the strength parameter dynamically in response to applied forces.
3Object-affected harmful factors
If the fastener clips are designed to break away under impact load, then cable protection is improved, but the device complexity increases
Solution Approach 1:
The break-away feature is applied locally only to the fastener clips rather than the entire cable bundle router structure. This localized application of the protective mechanism keeps the overall device simple while providing the necessary impact protection function where it is most needed.
Solution Approach 2:
The protective function is extracted into separate, independent fastener clip components that can be easily manufactured and assembled. By separating the protective function into discrete clips rather than integrating it into the main router structure, the design becomes simpler and more modular.
Data Source
AI summary
An impact releasable cable bundle router for a vehicle electrical system includes a base plate configured to couple to a vehicle component, a cable support extending outwardly from the base plate and including a cable receiving surface configured to receive an electrical cable, and a cable cover configured to couple to the cable support to secure the electrical cable therebetween. The cable cover includes a fastener clip to at least partially secure the cable cover to the cable support. The fastener clip is configured to intentionally break away from the cable cover under a predetermined load from a vehicle impact event to thereby release the electrical cable and cable cover and facilitate preventing pull out loads on an electrical connector of the electrical cable.