Cross-Reference to Related Application

[0001] This application claims priority to and the benefit of U.S. Provisional Application Serial No. 63/393,668 filed July 29, 2022, the disclosure of which is hereby incorporated by reference in its entirety.

Technical Field

[0002] The present disclosure relates generally to electrical cable dampers for high- voltage electric cables and connectors. Particularly, the present disclosure relates to electrical cable dampers arranged around an outer surface or circumference of high- voltage electrical cables and around an outer surface of electrical connectors.

Background

[0003] High-voltage electric cables and connectors in battery electric vehicles (BEVs) may be a significant source of noise, vibration, and harshness (NVH). NVH is typically created by the high-voltage electric cables in use in a BEV, and may be a source of discomfort to people present inside the vehicle cabin, which can generate complaints from the vehicle occupants.

Summary

[0004] In one aspect, the technology relates to an electrical cable damper arrangement including an electrical cable and one or more cable dampers arranged along a longitudinal axis of the electrical cable, each of the one or more cable dampers including an opening formed therein, the opening being configured to accommodate an outer surface of the electrical cable therethrough, and a material of each of the one or more cable dampers including a resin configured to absorb vibrations transmitted by the electrical cable.

[0005] In an example of the above aspect, the one or more cable dampers include a plurality of cable dampers, and the plurality of cable dampers are separated by a gap along the longitudinal axis of the electrical cable. In another example, the electrical cable is configured to transmit a voltage in a range of 100 V to 1000 V. In yet another example, the electrical cable is configured to transmit a current that is equal to or greater than 100 Amps. In other examples, the opening is a circular opening. In further examples, the opening in each of the one or more cable dampers is configured to fit the electrical cable snugly therein. In another example, a substantially entire inner surface of the opening in each of the one or more cable dampers is in direct contact with the outer surface of the electrical cable. In yet another example, the material of each of the one or more cable dampers includes at least one of an acryl resin and a silicone resin. In another example, the outer surface of the electrical cable is an outer circumference. [0006] In another aspect, the technology relates to an electrical connector damper arrangement that includes an electrical connector and at least one damper arranged on an outer surface of the electrical connector, the at least one damper covering a substantial portion of the outer surface of the connector, a material of the at least one damper including a resin configured to absorb vibrations transmitted by the electrical connector.

[0007] In various examples of the above aspect, a substantially entire inner surface of the at least one damper is in direct contact with the outer surface of the electrical connector. In other examples, the material of the at least one damper includes at least one of an acryl resin and a silicone resin.

[0008] In another aspect, the technology relates to an electrical cable damper arrangement that includes a plurality of electrical cables extending along a longitudinal axis, and one or more dampers arranged along a longitudinal axis of the plurality of electrical cables, each of the one or more dampers including a plurality of openings therein, each of the openings being configured to accommodate an outer surface of one of the plurality of electrical cables therethrough, and a material of each of the one or more dampers including a resin configured to absorb vibrations generated by the plurality of electrical cables.

[0009] In examples of the above aspect, the one or more dampers include a plurality of dampers, and the plurality of dampers are separated by a gap along the longitudinal axis. In another example, the plurality of electrical cables are configured to transmit a voltage in a range of 100 V to 1000 V. In yet another example, the plurality of electrical cables are configured to transmit a current that is greater than 100 Amps. In a further example, one or more of the plurality of openings are circular. In yet another example, the opening in each of the one or more dampers is configured to fit at least one of the electrical cables snugly therein. In a further example, a substantially entire inner surface of the opening in each of the one or more dampers is in direct contact with the outer surface of one of the electrical cables. In further examples, the material of each of the one or more dampers includes at least one of an acryl resin and a silicone resin. In yet another example, the outer surface of at least one of the plurality of electrical cables is an outer circumference.

Brief Description of the Drawings

[0010] The accompanying drawings, which are incorporated in and constitute a part of the description, illustrate several principles of the present disclosure. A brief description of the drawings is as follows.

[0011] FIGS. 1 A-1D are illustrations of a high-voltage electrical cable damper, in accordance with various examples of the disclosure.

[0012] FIGS. 2A-2D illustrate various connector dampers, in accordance with various principles of the present disclosure.

[0013] FIG. 3 illustrates a cable damper, in accordance with various principles of the present disclosure.

Detailed Description

[0014] High-voltage electric cables in battery electric vehicles (BEVs) may be a significant source of vibrations. Such vibrations are typically created by high-voltage electric cables and may be a source of noise inside the vehicle cabin, which can generate complaints from vehicle occupants. For example, high voltage may include a voltage in a range of 100V to 1000V. In another example, the high-voltage electrical cables may transmit a current that is greater than 100 Amps. Accordingly, the user of dampers on high-voltage cables may lower the natural frequency of the cables and reduce NVH issues. For example, reducing the amplitude of the vibration wave of the cable may reduce the NVH inside the vehicle cabin, and consequently reduce complaints from the vehicle occupants.

[0015] In various examples, a damper installed or arranged around an outer surface or circumference of a high-voltage electrical cable may operate as a shock- or vibrationabsorbing device that reduces, minimizes, or eliminates any shock or vibration generated by the high-voltage cables. For example, the cable damper may dissipate the energy that can potentially cause vibration of the cable. The cable damper may also be provided in varying sizes to accommodate for various applications, electric cable sizes, NVH issues, and the like. In addition, the cable damper may be installed in various locations on the same cable and can be moved to different locations as needed to reduce, minimize, or eliminate NVH issues. In addition, a cable damper may increase the life of the electrical cable by reducing the vibrations to which the electrical cable may be subjected to during its lifetime and thus reducing the possibility of the cable breaking due to the vibrations.

[0016] FIGS. 1 A-1D are illustrations of a high-voltage electrical cable damper arrangement 100, in accordance with various examples of the disclosure. In various examples, a cable damper 110 illustrated in FIG. 1 A may be made of, or include, a rigid material that is sufficiently rigid to be harnessed to a static portion of the vehicle such as, e.g., the chassis of the vehicle. In other examples, the cable damper 110 may also include a softer material such as, e.g., a shock-absorbing resin such as an acryl base resin and/or a silicone base resin, which have low elasticity and act as shock absorbers to dampen the vibrations generated or transmitted by an electrical cable 120.

[0017] In various examples, the cable damper arrangement 100 includes the cable damper 110 arranged around an outer surface or circumference of the electrical cable 120 such as, e.g., a high-voltage electrical cable 120, in a radial direction thereof so that the electrical cable 120 passes through an opening, e.g., a circular opening, within the cable damper 110, as illustrated in more detail in FIG. 1C. In various examples, although a circular opening is discussed herein and is illustrated in the drawings, other types of openings may be used herein such as, e.g., openings of different shapes. In an example, the circular opening in cable damper 110 is configured to fit the electrical cable 120 snugly therein. In yet another example, a substantially entire inner surface of the circular opening in the cable damper 110 is in direct contact with an outer surface or circumference of the electrical cable 120. In other examples, the cable damper 110 is a high-voltage cable damper 110, and the cable 120 is a high-voltage electrical cable 120. In other examples, the cable damper 110 has a thickness “T,” as illustrated in FIG. 1C, and the magnitude of the thickness T may be dependent on several parameters including, e.g., the amount of voltage transmitted through the electrical cable 120, the thickness of the electrical cable 120, the material(s) of the electrical cable 120, the material(s) of the cable damper 110, the amount of NVH generated in the vehicle, and the like.

[0018] In various examples, as illustrated in FIG. ID, when the electrical cable 120 is sufficiently long, it may be advantageous to have more than one damper 110 disposed alongside the length or the longitudinal axis of the electrical cable 120. For example, FIG. ID illustrates an example where the length of the cable 120 suggests or requires the addition of two cable dampers 110, the cable dampers 110 being separated by a predetermined distance along the length or longitudinal axis of the electrical cable 120. In examples, both cable dampers 110 may include an opening, e.g., a circular opening, therein and may be disposed around an outer surface or circumference of the electrical cable 120 in a radial direction thereof so that the electrical cable 120 passes through the opening in each cable damper 110. In various examples, although a circular opening is discussed herein and illustrated in the drawings, other types of openings may be used herein such as, e.g., openings of different shapes. In an example, the circular opening in each of the cable dampers 110 is configured to fit the electrical cablel20 snugly therein. In yet another example, a substantially entire inner surface of the circular opening in each of the cable dampers 110 is in direct contact with the outer surface or circumference of the electrical cable 120. In another example, because more than one cable damper 110 is arranged along the length or longitudinal axis of the electrical cable 120, a sufficient amount of dampening may be provided to the electrical cable 120 to reduce, minimize, or eliminate NVH issues resulting from unwanted vibrations generated or transmitted by the electrical cable 120. In various examples, although two cable dampers 110 are illustrated in FIG. ID, more than two cable dampers 110 may be arranged on the electrical cable 120 based on the physical characteristics of the electrical cable 120 such as, e.g., length, thickness, material, and the like.

[0019] FIGS. 2A-2D illustrate various cable damper and connector arrangements, in accordance with various principles of the present disclosure. FIG. 2A illustrates a connector damper arrangement 200, in accordance with examples of the disclosure. For example, a connector 220 is connected to a plurality of electrical cables 210 such as, e.g., high-voltage electrical cables 210, and a connector damper 230 may be arranged to cover the connector 220. For example, the connector damper 230 may be formed, e.g., removably formed, on substantially the entire outer surface of the connector 220, so that substantially an entire outer surface of the connector 220 is in direct contact with a surface of the connector damper 230. As a result, any vibrations or other noise generated or transmitted by the connector 220 may be dampened by the connector damper 230. In the example illustrated in FIG. 2A, the electrical cables 210 do not have a cable damper arranged thereon, but in other examples, one or more of the electrical cables 210 may have a cable damper arranged on an outer surface or circumference thereof, similarly to the cable damper 110 discussed above with respect to FIGS. 1A-1D.

[0020] In examples, FIG. 2B illustrate a connector (not shown) covered by a connector damper 232 and connected to an electrical cable 212. FIG. 2B also illustrates a cylindrical cable damper 222 arranged around an outer surface or circumference of the electrical cable 212 in a radial direction thereof so that the electrical cable 212 passes through an opening in the cylindrical cable damper 222. In various examples, the connector damper 232 may have substantially the same shape as the underlying connector so as to cover a significant portion of the connector and provide a sufficient amount of dampening of any vibrations generated or transmitted by the connector.

Accordingly, in various examples, the cable damper 222 and the connector damper 232 may together provide a sufficient amount of dampening of any vibration of the electrical cable 212 to reduce, minimize, or eliminate any NVH issues that may be experienced inside, e.g., a vehicle cabin.

[0021] In other examples, FIG. 2C illustrates a connector (not shown) covered by a connector damper 234 and connected to a plurality of electrical cables 214. In examples, each of the electrical cables 214 has a cable damper 224 arranged around an outer surface or circumference thereof so that each electrical cable 214 passes through an opening in the corresponding cable damper 224. Accordingly, in examples, any vibration generated or transmitted by each electrical cable 214 and/or by the connector may be dampened, reduced, or eliminated by the combination of the connector damper 234 and the cable damper 224.

[0022] In yet other examples, FIG. 2D illustrates a connector (not shown) covered by a connector damper 236 and connected to an electrical cable 216. In examples, a cable damper 226 is arranged around an outer surface or circumference of the cable 216 so that the electrical cable 216 passes through an opening within the cable damper 226. Accordingly, in examples, any vibration generated or transmitted by the electrical cable 216 and/or by the connector may be dampened, reduced, or eliminated by the combination of the connector cable 236 and the cable damper 226.

[0023] FIG. 3 illustrates a cable damper arrangement 300, in accordance with various principles of the present disclosure. In various examples, a cable damper 310 includes two portions, a rigid cable damper portion 310A and a softer cable damper portion 310B. For examples, the rigid cable damper portion 310A may be sufficiently rigid to be tied to a static object such as, e.g., the chassis of a vehicle, in order to stabilize the cable damper 310 and minimize, reduce, or eliminate any NVH issues that may be caused by vibrations of the electrical cables therein. In examples, the cable damper 310 may also include a softer portion 310B, the softer portion 310B being configured to receive a plurality of electrical cables (not shown) therethrough. For example, the softer portion 310B may include a plurality of openings 320, each of the openings 320 being configured to pass an electrical cable therethrough. In various examples, although the openings 320 are described as circular openings in FIG. 3, other types of openings may be used herein such as, e.g., openings of different shapes. In the example illustrated in FIG. 3, the cable damper arrangement 300 includes two openings 320 configured to receive electrical cables therein. However, other examples of the present disclosure may include more than two openings 320, each of the openings 320 being configured to receive an electrical cable therethrough. Accordingly, the same cable damper 310 may dampen, reduce, or eliminate NVH issues caused by vibrations in a plurality of electrical cables when the electrical cables are received through the openings 320 therein.

[0024] Various examples of the current disclosure may be represented by a plurality of clauses as discussed below.

[0025] Clause 1 : An electrical cable damper arrangement including an electrical cable; and one or more cable dampers arranged along a longitudinal axis of the electrical cable; each of the one or more cable dampers including an opening formed therein, the opening being configured to accommodate an outer surface of the electrical cable therethrough; and a material of each of the one or more cable dampers including a resin configured to absorb vibrations transmitted by the electrical cable.

[0026] Clause 2: The electrical cable damper arrangement of clause 1, wherein: the one or more cable dampers include a plurality of cable dampers; and the plurality of cable dampers are separated by a gap along the longitudinal axis of the electrical cable. [0027] Clause 3 : The electrical cable damper arrangement of clause 1 or clause 2, wherein the electrical cable is configured to transmit a voltage in a range of 100 V to 1000 V. [0028] Clause 4: The electrical cable damper arrangement of any one of clauses 1-3, wherein the electrical cable is configured to transmit a current that is equal to or greater than 100 Amps.

[0029] Clause 5: The electrical cable damper arrangement of any one of clauses 1-4, wherein the opening in each of the one or more cable dampers is a circular opening. [0030] Clause 6: The electrical cable damper arrangement of any one of clauses 1-5, wherein the opening in each of the one or more cable dampers is configured to fit the electrical cable snugly therein.

[0031] Clause 7: The electrical cable damper arrangement of any one of clauses 1-6, wherein a substantially entire inner surface of the opening in each of the one or more cable dampers is in direct contact with the outer surface of the electrical cable.

[0032] Clause 8: The electrical cable damper arrangement of any one of clauses 1-7, wherein the material of each of the one or more cable dampers includes at least one of an acryl resin and a silicone resin.

[0033] Clause 9: The electrical cable damper arrangement of any one of clauses 1-8, wherein the outer surface of the electrical cable has an outer circumference.

[0034] Clause 10: An electrical connector damper arrangement including: an electrical connector; and at least one damper arranged on an outer surface of the electrical connector, the at least one damper covering a substantial portion of the outer surface of the connector; a material of the at least one damper including a resin configured to absorb vibrations transmitted by the electrical connector.

[0035] Clause 11 : The electrical connector damper arrangement of clause 10, wherein a substantially entire inner surface of the at least one damper is in direct contact with the outer surface of the electrical connector.

[0036] Clause 12: The electrical connector damper arrangement of clause 10 or clause 11, wherein the material of the at least one damper includes at least one of an acryl resin and a silicone resin.

[0037] Clause 13: An electrical cable damper arrangement including: a plurality of electrical cables extending along a longitudinal axis; and one or more dampers arranged along a longitudinal axis of the plurality of electrical cables; each of the one or more dampers including a plurality of openings therein, each of the openings being configured to accommodate an outer surface of one of the plurality of electrical cables therethrough; and a material of each of the one or more dampers including a resin configured to absorb vibrations generated by the plurality of electrical cables.

[0038] Clause 14: The electrical cable damper arrangement of clause 13, wherein the one or more dampers include a plurality of dampers, and the plurality of dampers are separated by a gap along the longitudinal axis.

[0039] Clause 15: The electrical cable damper arrangement of clause 14, wherein the plurality of electrical cables are configured to transmit a voltage in a range of 100 V to 1000 V.

[0040] Clause 16: The electrical cable damper arrangement of clause 14 or clause 15, wherein the plurality of electrical cables are configured to transmit a current that is greater than 100 Amps.

[0041] Clause 17: The electrical cable damper arrangement of any one of clauses 13-

16, wherein one or more of the plurality of openings are circular.

[0042] Clause 18: The electrical cable damper arrangement of any one of clauses 13-

17, wherein each opening in each of the one or more dampers is configured to fit at least one of the electrical cables snugly therein.

[0043] Clause 19: The electrical cable damper arrangement of any one of clauses 13-

18, wherein a substantially entire inner surface of each opening in each of the one or more dampers is in direct contact with the outer surface of one of the electrical cables. [0044] Clause 20: The electrical cable damper arrangement of any one of clauses 13-

19, wherein the material of each of the one or more dampers includes at least one of an acryl resin and a silicone resin.

[0045] Clause 21 : The electrical cable damper arrangement of any one of clauses 13-

20, wherein the outer surface of at least one of the plurality of electrical cables is an outer circumference.

[0046] This disclosure described some examples of the present technology with reference to the accompanying drawings, in which only some of the possible examples were shown. Other aspects can, however, be embodied in many different forms and should not be construed as limited to the examples set forth herein. Rather, these examples were provided so that this disclosure was thorough and complete and fully conveyed the scope of the possible examples to those skilled in the art.

[0047] When the terms "about" or “substantially” are used in this specification in connection with a numerical value, it is intended that the associated numerical value include a tolerance of ±10% around the stated numerical value. Moreover, when reference is made to percentages in this specification, it is intended that those percentages are based on weight, i.e., weight percentages. The expression “up to” includes amounts of zero to the expressed upper limit and all values therebetween. When ranges are specified, the range includes all values therebetween such as increments of 0.1%. Moreover, when the words "generally" and "substantially" are used in connection with geometric shapes, it is intended that precision of the geometric shape is not required but that latitude for the shape is within the scope of the disclosure. Although the tubular elements of the embodiments may be cylindrical, other tubular cross-sectional forms are contemplated, such as square, rectangular, oval, triangular and others.

[0048] Various modifications and alterations of this disclosure will become apparent to those skilled in the art without departing from the scope and spirit of this disclosure, and it should be understood that the inventive scope of this disclosure is not to be unduly limited to the illustrative examples set forth herein.