Protected Frame-Rail Routing for EV Battery Cables and Coolant Lines

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Solution Overview

Problem

Existing vehicles with electrical energy systems face challenges in efficiently routing and protecting high-voltage cables and coolant lines within the vehicle frame, which can lead to damage and interference with other components.

Innovation Solution

The vehicle design incorporates frame rails that enclose and protect high-voltage cables and coolant lines, using a combination of frame rails and battery packs to create a protected pathway for these components, minimizing exposure and potential damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If high-voltage cables and coolant lines are routed through the vehicle frame, then electrical energy systems can be established, but the cables and lines are exposed to potential damage and interference

Engineering Contradiction:

Improveprotection of cables and linesVSAvoidexposure to damage and interference

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies nesting by placing high-voltage cables and coolant lines inside the hollow interior of frame rails. The frame rails serve as protective enclosures that integrate the cable routing within their structural geometry, thereby protecting the cables from external damage while maintaining frame strength.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The patent introduces protective sleeves or conduits as intermediary elements between the high-voltage cables and the frame rail interior walls. These intermediaries provide an additional layer of protection and isolation, preventing direct contact between cables and potential sources of damage.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If cables are routed along frame rails, then electrical connections can be made, but space within the frame is occupied

Engineering Contradiction:

Improvecable routingVSAvoidspace utilization

Core Design Contradiction:

Ease of manufactureVSVolume of moving object

Solution Approach 1:

The frame rails serve multiple functions: they provide structural support for the vehicle body and simultaneously serve as protective conduits for high-voltage cables and coolant lines. This multi-functionality eliminates the need for separate cable routing structures, optimizing space utilization while maintaining ease of manufacture.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If frame rails enclose cables, then protection is enhanced, but frame structure complexity increases

Engineering Contradiction:

Improvecable protectionVSAvoidframe structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the cable protection function with the frame rail structure itself. Rather than adding separate protective enclosures, the design integrates cable routing within the hollow interior of existing frame rails, thereby enhancing protection without significantly increasing structural complexity.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20250214653A1Vehicle with protected routing

Publication Date: 2025.07.03 OSHKOSH CORPORATION

AI summary

An electrified refuse vehicle includes a chassis including a first frame rail and a second frame rail, a body supported on the chassis, a battery pack supported on the chassis, and a power cable extending along the first frame rail. The power cable is enclosed by a combination of the first frame rail and the battery pack.