Deformable Cable Protection Device for Electric Powertrains

Solution Overview

Problem

Existing protection mechanisms for high voltage cables in electric vehicles are inadequate in preventing access to workers after severe impacts, as they may not effectively isolate cables from becoming accessible due to vehicle deformation, leading to potential electrocution risks.

Innovation Solution

A protection device with a deformable zone made of a cellular rubber mesh and metal reinforcement, which can absorb impact-induced position changes and deform, combined with clip fastening means that can be easily integrated with existing powertrain elements, ensuring the cables remain inaccessible even after a violent impact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If rigid protective devices are used to protect high-voltage cables, then mechanical strength is improved, but the device cannot accommodate position changes between powertrain components during impact

Engineering Contradiction:

Improvemechanical strengthVSAvoidadaptability to position changes

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The protective device uses a flexible wall made of elastomeric material that can deform to accommodate position changes between powertrain components during impact, while still providing protection. The flexible material allows the device to adapt to longitudinal separations without compromising the protective function.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The protective device combines elastomeric material with reinforcing elements to create a composite structure. This composite material provides both the flexibility needed to accommodate position changes and the mechanical strength required for effective protection during impact.

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If the protective device is made fully deformable to accommodate impact, then adaptability is improved, but mechanical rigidity and protective capability deteriorate

Engineering Contradiction:

Improveadaptability to position changesVSAvoidmechanical rigidity

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The protective device uses a flexible wall made of elastomeric material that can deform to accommodate position changes between powertrain components during impact, while still providing protection. The flexible material allows the device to adapt to longitudinal separations without compromising the protective function.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The protective device combines elastomeric material with reinforcing elements to create a composite structure. This composite material provides both the flexibility needed to accommodate position changes and the mechanical strength required for effective protection during impact.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If standard fastening methods are used, then ease of manufacture is improved, but integration with existing powertrain components without modification becomes difficult

Engineering Contradiction:

Improveease of manufactureVSAvoidadaptability to existing powertrain

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The protective device incorporates fastening means designed to engage with common features found on existing powertrain components, such as reinforcing ribs. This universal approach allows the device to be integrated into various powertrain configurations without requiring modifications to the existing components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 effectively keeps high voltage cables inaccessible to workers during and after a vehicle overturn, minimizing electrocution risks by absorbing deformation and maintaining mechanical rigidity through fusible points, while being cost-effective and adaptable to existing powertrain designs.

Implementation Method 1

said deformable zone comprises a honeycomb mesh made of high elastic resistance rubber. The use of a honeycomb mesh in this material makes it possible to effectively absorb the positional differences between the two elements of the powertrain in the event of an impact.

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

the wall comprises a metal reinforcement having fusible points at the level of the deformable zone. The metal reinforcement ensures the proper mechanical rigidity of the protective device, the fusible points allowing the deformable zone to deform despite this rigidity.

Methodology Applied

Scientific EffectMetal reinforcement providing mechanical rigidity:

Data Source

PatentEP3344487B1Device for protecting power cables of an electrical powertrain

Publication Date: 2019.09.11 RENAULT SA

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AI summary

The invention relates to a device (SK) for protecting power cables connecting a first element of an electrical powertrain of a vehicle to a second element of said electrical powertrain, said protection device (SK) comprising first means for attachment (AG1, AG2) to said first element. Said protection device (SK) is characterized in that it further comprises: - second means for attachment (AG3) to said second element, -a wall (P) for encompassing said power cables in a space extending between said wall (P) and said powertrain, - said wall (P) comprising a deformable area (ZD) capable of deforming longitudinally between said first attachment means (AG1, AG2) and said second attachment means (AG3).