Conductive Cable Bracket for EV Battery Strain Relief
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Solution Overview
Problem
In hybrid and electric vehicles, high voltage cables experience strain and electrical noise due to bending near terminal connections and vibrations, which can lead to connection failures and interference.
Innovation Solution
A cable bracket system with a conductive base member, clamp member, and clamping fastener, featuring concave inner surfaces and protrusions to secure high voltage cables and provide electrical grounding, reducing strain and noise by clamping the cables between the base and clamp arms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If high voltage cables are bent near terminal connections to achieve tight packaging, then space utilization is improved, but strain on terminal connections and cables increases
Solution Approach 1:
A cable bracket is introduced as an intermediary component between the cable and terminal connection. The bracket includes a base member with a first arm and a second arm, creating a support structure that intercepts and redistributes mechanical strain away from the terminal connection, allowing cable routing flexibility without compromising connection integrity
Solution Approach 2:
The cable bracket is divided into separate functional segments: a base member with multiple arms, each arm having concave inner surfaces for cable reception, and aperture members for fastening. This segmentation allows independent optimization of each component's function while maintaining overall structural integrity and strain distribution
2Adaptability or versatility
If cables are allowed to vibrate relative to terminal connections, then flexibility in cable routing is improved, but strain on terminal connections increases
Solution Approach 1:
The cable bracket serves as a mediator that decouples the cable from direct attachment to the terminal connection. The bracket's rigid structure with concave arms provides a stable mounting point that prevents vibration-induced strain while still allowing cable routing flexibility through its geometric design
Solution Approach 2:
The cable is positioned and secured within the concave inner surfaces of the bracket arms before final connection to the terminal. This preliminary positioning action ensures proper cable alignment and strain distribution is established prior to electrical connection, preventing vibration-related damage
3Object-affected harmful factors
If shielding material is added to reduce electrical noise, then electromagnetic interference is reduced, but cable complexity and size increase
Solution Approach 1:
The cable bracket with its conductive aperture members acts as an intermediary grounding structure. The apertures provide dedicated electrical connection points that facilitate shielding layer grounding without requiring complex integrated shielding structures within the cable itself, simplifying cable design while maintaining noise reduction effectiveness
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 bracket system effectively relieves strain on high voltage cables, maintains electrical contact, and grounds the shielding layer, thereby reducing noise and interference, enhancing the reliability of terminal connections.
Implementation Method 1
The layer of shielding material generally is electrically coupled to an electrical ground (e.g. vehicle frame, or ground circuit)... The cable bracket system... grounds the shielding layer, thereby reducing noise and interference
Implementation Method 2
The clamping fastener is received through the apertures of the base bridge and the clamp bridge and secures the clamp member to the base member in electrical contact therewith... effectively relieves strain on high voltage cables, maintains electrical contact
Data Source
AI summary
A vehicle battery pack system includes a cable bracket that has a conductive base, and a clamp. The base includes a mount, base arm, and base bridge. The mount is configured to be mounted to an electrical ground. The base bridge defines an aperture and fixedly couples the mount to the base arm. The base arm has a concave surface. The clamp includes a clamp arm and clamp bridge. The clamp bridge defines an aperture. The clamp arm is fixedly coupled to the clamp bridge and has a concave surface opposing the concave surface of the base arm. A fastener is received through the apertures to couple the clamp to the base. A protrusion extends radially inward from at least one of the concave surfaces. The protrusion is coupled for electrical communication with the mount to transmit electricity between the protrusion and the electrical ground.