Cable Fixing System with Elastic Wedging for Battery Bars

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Solution Overview

Problem

Existing systems for attaching cables to conductive bars in electric or hybrid vehicle batteries fail to effectively prevent vibrations, leading to noise and fatigue issues, requiring additional components and complex assembly processes.

Innovation Solution

A cable fixing system with an elastic element that compresses perpendicular to the support plane, allowing for simultaneous cable fixation and bar wedging, utilizing a single component that can be easily integrated into the battery assembly, reducing costs and simplifying management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate components are used for cable fixing and bar wedging, then both functions can be performed, but device complexity increases and assembly time is extended

Engineering Contradiction:

Improvecable fixation and bar stabilizationVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the cable fixing function and the bar wedging function into a single integrated component. The fixing system includes a clamp body with a clamp jaw for securing the cable and an elastic element that simultaneously provides wedging force against the flat conductive bar, eliminating the need for separate wedging components and simplifying the overall assembly structure.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single fixing component performs multiple functions: it secures the flexible cable to the rigid bar through the clamp jaw, prevents bar vibrations through the elastic element's wedging action, and provides structural support. This multi-functional design reduces the number of parts needed while maintaining all necessary functions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If multiple components are used for cable fixing and bar wedging, then both functions can be achieved, but assembly time increases

Engineering Contradiction:

Improvecable fixation and bar stabilizationVSAvoidassembly time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The elastic element is pre-configured within the fixing component to automatically engage and wedge the bar when the component is installed. This preliminary arrangement of the wedging mechanism eliminates the need for separate assembly steps for bar stabilization, reducing assembly time while ensuring reliable vibration prevention.

Inventive Principle:

Principle #10Preliminary action

3Device complexity

If conventional cable fixing systems are used without integrated wedging, then assembly is simpler, but bar vibrations cause noise and fatigue failures

Engineering Contradiction:

Improvefixing system structureVSAvoidbar vibrations, noise, and fatigue

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The patent addresses the harmful vibrations by using the elastic element to apply continuous wedging pressure against the bar, converting the potential harm of vibration-induced fatigue into a beneficial stabilizing force. The elastic material's natural compliance allows it to absorb and dampen vibrations while maintaining secure contact, thereby eliminating noise and preventing fatigue failures.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The elastic element acts as an intermediary between the fixing component and the conductive bar, providing a compliant interface that reduces vibration transmission. This intermediary element absorbs vibrational energy and prevents direct rigid contact that would amplify vibrations and cause noise, while still maintaining the necessary mechanical connection.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 system effectively secures cables and prevents bar vibrations in a single operation, reducing noise and fatigue, while simplifying the assembly process and managing fewer components, thus lowering costs and enhancing reliability.

Implementation Method 1

at least one elastic element facing the outside of the fixing system, this element having an elasticity in the direction perpendicular to the support plane and being compressed by the cover, or by the top of one of the batteries, or by the cover and by the top of a are batteries

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentEP3574558B1Battery set with system for securing cables on a rigid conductive bar

Publication Date: 2021.03.17 PSA AUTOMOBILES SA

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Figure 4~5

AI summary

The invention relates to a system for securing cables (2) intended to be secured on a rigid conductive bar (4) producing battery connections for an electric or hybrid vehicle, this system comprising a holding loop intended for receiving at least one cable (2), and a securing device intended to be secured on the bar (4) which is flat, this device having a longitudinal direction and a support plane corresponding respectively to the longitudinal direction of this bar (4), and to a support surface on the flat part of this bar (4), characterised in that it comprises at least one resilient element (20, 22) turned towards the outside of the securing system, having a resilience in the direction perpendicular to the support plane.