FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION (See section 10, rule 13)
“CABLE ROUTING STRUCTURE IN A VEHICLE”
MINDA CORPORATION LIMITED, an Indian company of E-5/2, Chakan Industrial Area, Phase- III M.I.D.C. Nanekarwadi, Tal: Khed, Dist., Pune, Maharashtra, 410-501, India
The following specification particularly describes the invention and the manner in which it is to be performed.

TECHNICAL FIELD
[001] The present disclosure generally relates to field of automobiles. Particularly, but not exclusively, the present disclosure relates to wire routing structures for vehicles. Further, embodiments of the present disclosure provide an over-molding structure provided to the wires to maintain a desired orientation of wires while routing the wires in the vehicle.
BACKGROUND
[002] On a vehicle, power has to be suitably fed, for example, from an alternator (power generator) or a battery which is a main power supply unit to each of a huge number of various electrical components. Therefore, in order to supply power to different electrical components plurality of wires has to be routed through out the vehicle. The plurality of wires are configured to pass through different planes and requires plurality of bends to supply the power to electrical components located at peripheral regions of the vehicle. The plurality of wires passing through out the vehicle are usually clamped to chassis of the vehicle by means of mechanical fasteners or clamps. The clamps may result in breaking of wires after a certain period of time due to application of various loads exerted on the vehicle during motion of the vehicle.
[003] The power supply unit and each of the various electrical components are connected by wire harness generally constituted of a wire bundle which is an aggregate of various kinds of electric wires connecting a power supply and electrical components. However, the structure of the wire harness tends to be complicated with an increase in electrical components mounted on a vehicle. As a result, there is an increase in number of wires which in turn complexes the routing of wires along frame of the vehicle.
[004] In general, four wheeled vehicles, including but not limited to, vehicles having internal combustion engines, hybrid electric vehicles (HEVs), electric vehicles (EVs), and the like, a wire/cable connecting a power generating motor and a battery, which are generally installed in a front and/or rear part of the vehicle, is disposed along a front and/or

rear direction of the vehicle. It is quite obvious to a person skilled in the art that the cable must be prevented from being broken or damaged in an emergency, which includes, but not limited to, collision of the vehicle, so that a high voltage electric shock may not be exerted to an occupant or to a rescuer. The battery cables which are in general short in length, gets twisted and turned quite often and are clamped for the connections. The battery cable routing in the vehicle required specific routing path (changing planes) without adequate clamping provision available due to packaging constraint. High Cross-section (50mm²) Battery cables are not flexible for retaining the intended routing in the vehicle, which becomes critical & need required clearances from interface components to avoid any mechanical/thermal issues.
[005] The conventional methods for battery cable or wire twisting requires high manufacturing cost for the protective cover because of the complex shape of the protective cover. At the same time, the cable portions around the protective cover are also exposed. So, there might be a probability of cable getting broken or damaged at the portions around the protective cover by interfering with other components. The protective cover may be formed to cover the otherwise exposed portion of the cable, but this method leads to even higher manufacturing cost for the protective cover.
[006] In view of above, there is an immense need in the art to provide a solution to the battery cable routing structure for vehicles, which can reliably prevent the cable from being broken or damaged and can reduce the manufacturing cost significantly.
SUMMARY OF THE DISCLOSURE
[007] The present disclosure relates to construction of over-molding material covering the outer surface of the cable to achieve desired orientation of cable as required in the vehicle. Further, the solution is also cost effective as it does not require covering of cables from protective covers.

[008] The objective of the invention is to provide a solution to the battery cable routing structure for vehicles, which can reliably prevent the cable from being broken or damaged, and can reduce the manufacturing cost significantly by optimizing the cable length and relieve the stress on terminal/battery post loosening.
[009] The over-molding of material around an insulating layer of cable/wire provides sufficient stiffness to the cable when the cable is bend during routing. The solution avoids clipping provisions, customized channel designs to maintain the orientation and layout of battery cables. The solution also helps to improve cable routing structure for the vehicles. The 90-degree orientation and for that matter, orientation at any angle is achieved by way of over-molding material at the angular juncture or bending region of the cable. This will avoid the clamping of the battery cables which may give rise to broken cables with the continual vibrations and aging.
[010] The limitations of the prior arts are addressed to a great extent by a cable routing structure for a vehicle, as disclosed in the present disclosure.
[011] The cable routing structure for a vehicle comprises a cable having a first end, a second end and an intermediate portion. The intermediate portion is defined between the first end and the second end. The intermediate portion comprises plurality of bend regions to facilitate routing of the cable within the vehicle. Each of the plurality of bend regions are encapsulated with a guide member, such that the guide member provides support to the cable during routing of the cable for connecting electronic components of the vehicle.
[012] In an embodiment, an inner surface of the guide member abuts with an outer surface of the cable.
[013] In an embodiment, the guide member is formed from a composite material having polypropylene and through a molding process.

[014] In an embodiment, the guide member comprises at least two slots formed on an outer surface of the guide member.
[015] In an embodiment, the cable comprises a plurality of wires enclosed by an insulator layer along length of the plurality of wires, and the cable is configured to connect a power source with an isolator switch of the vehicle.
[016] In an embodiment, molding of the guide member is done on the insulator layer at the bend regions of the cable.
[017] In an embodiment, the first end of the cable is connected with a first terminal connector, and the first terminal connector is configured to connect the cable with the power source of the vehicle.
[018] In an embodiment, the second end is connected with a second terminal connector, and the second terminal connector is configured to connect the cable with the isolator switch of the vehicle.
[019] In another embodiment, a method for manufacturing a cable routing structure for a vehicle is disclosed. The method comprises: marking a cable connecting a power source with an isolator switch of the vehicle, such that the marking indicates plurality of bend regions of the cable; placing the cable with the markings inside a mold to facilitate molding of a guide member on an outer surface of the cable and in between the markings thereof; and inspecting the cable formed with the guide member at the respective bend regions of the cable.
[020] In another embodiment, a guide member for a cable is disclosed. The guide member comprises an over-mold structure formed over an insulator layer of the cable and at each of plurality of bend regions by a molding process.

[021] It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined together to form a further embodiment of the disclosure.
[022] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects and features described above, further aspects and features will become apparent by reference to the drawings and the following detailed description
BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS
[023] Further aspects and advantages of the present invention will be readily understood from the following detailed description with reference to the accompanying figure(s). The figure(s) together with a detailed description below, are incorporated in and form part of the specification, and serve to further illustrate the embodiments and explain various principles and advantages, in accordance with the present invention wherein:
[024] FIG.1 illustrates a top view of over-molded cable, in accordance with the embodiment of the present disclosure;
[025] FIG. 2 illustrates a cross-sectional view of cable of FIG. 1;
[026] FIG. 3 illustrates a perspective view of the cable molded with an over-molding material at bends, in accordance with a preferred embodiment of the present disclosure;
[027] FIG. 4 illustrates a perspective view of the cable molded with an over-molding material connecting a power source with an isolator switch of a vehicle, in accordance with a preferred embodiment of the present disclosure;
[028] Skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and have not necessarily been drawn to scale. For example, the dimensions of

some of the elements in the drawings may be exaggerated relative to other elements to help to improve understanding of embodiments of the present invention.
DETAILED DESCRIPTION
[029] While the invention is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the figures and will be described in detail below. It should be understood, however that it is not intended to limit the invention to the particular forms disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternative falling within the spirit and the scope of the invention.
[030] The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a system, device that comprises a list of components does not include only those components but may include other components not expressly listed or inherent to such setup or device. In other words, one or more elements in a system or apparatus proceeded by "comprises... a" does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
[031] Accordingly, the present disclosure provides a cable routing structure to facilitate precise and stiff routing of cables to connect a power source with a plurality of electrical components in a vehicle. The cable routing in the vehicle is provided in order to transit power from the power source preferably a battery to different electrical and electronic components. The transmission of power from the power source facilitates working of said components in respective manner. The cables connecting the power source to said components are routed in a predefined pathway and the routing of the cables depend on the packaging space available within the vehicle frame and mounting of respective components of the vehicle. During routing of cables, the cables are aligned at different angles and in different planes based on the packaging space available within the vehicle frame.

[032] The present application provides the cable routing structure comprising a cable having a first end, a second end and an intermediate portion. The intermediate portion is defined between the first end and the second end of the cable. The cable is configured to connect plurality of electronic components of the vehicle. The intermediate portion of the vehicle comprises at least one bend region or a plurality of bend regions to facilitate routing of cable within the vehicle. Each of the plurality of bend regions is encapsulated with a guide member. The guide member may also be referred to as an over-mold structure or a bend cover. The guide member provides support and stiffness to the cable during routing of the cable for connecting different electronic and/or electrical components of the vehicle. The guide member is molded on an outer surface of the cable at each of the plurality of bend regions and eliminates the requirement of clamps, brackets, adhesives and likewise to support or hold the cable in a predefined orientation.
[033] The guide member is formed from a composite material having polypropylene in major proportion preferably polypropylene - fire retardant material. When combined with the polypropylene material, natural fibres act as an effective alternative to glass fiber with the advantage of excellent environmental performance, good thermal properties, and high resilience. Polypropylene is a low-Density material as such, it significantly reduces costs and fuel consumption associated with more substantial vehicle. Therefor the use polypropylene facilitates decrease in a vehicle weight, making them more environmentally and economically appealing. The guide member formed on an outer surface of the cable by a molding process, preferably injection molding but not limited to the same. The molding of the guide member at each of the plurality of bend regions provide support and stiffness to the cable at respective bend regions and at the same time eliminates the requirement of clamps to keep the cable in the predefined orientation.
[034] The following paragraphs describe the present disclosure with reference to FIGS.1 to 4. In the figures, the same element or elements which have similar functions are indicated by the same reference signs.

[035] Referring to FIG. 1, a cable routing structure (100) is depicted, such that the cable routing structure (100) (hereinafter may referred as “structure”) is configured to connect multiple electrical and/or electronic components of a vehicle (not shown in FIGS.). The structure (100) comprises a cable (1) configured to transmit power to different electronic components of the vehicle. The cable routing is done to connect plurality of electrical components mounted at different locations in a vehicle with the power source. The cable routing is defined as allowing the cables to pass along a frame of the vehicle from a power source of the vehicle to the respective electronic components. Referring to FIG. 1, a bend region (10) of the cable (1) provided with a guide member (2) is depicted. The guide member (2) is formed from a composite material having Polypropylene material (PP material). However, the guide member (2) may be formed from any suitable material that provides stiffness and support to the cable (1) during change in orientation of the cable (1).
[036] Referring to FIG. 2, the cable (1) comprises of a plurality of wires (11) enclosed inside an insulator layer (12). The wires (11) are conductors of electricity and may be formed from any conducting material like copper but not limited to the same. The wires (11) are configured to transmit electricity or power from the power source to specific electrical and/or electronic components mounted on the vehicle. The insulator layer (12) is made up of an insulative resin material. One or more layers of insulator may be provided to the wires to prevent leakage of current and also prevents dispersion of electromagnetic field to interrupt working of other mechanical or electrical components surrounding the cable (1). The insulator layer (12) surrounding the plurality of wires (11) are adapted to prevent flow of current from the wires (11) into the surrounding or components mounted in peripheral region of the wires (11).
[037] In an embodiment of the present disclosure, the guide member (2) is provided at plurality of bend regions (10) and/or at those portions of the cable (1) where the cable (1) is changing plane. Change in plane of the cable (1) is required during routing of the cable (1) along a chassis or frame of the vehicle to connect plurality of electrical components with one another. Change in plane of the cable (1) is defined when the cable (1) is allowed to bend or configured to change angular orientation in accordance with the frame structure

or available space in the vehicle to facilitate routing of the cable (1). The bending of cable (1) requires external means to provide support to the cable (1) at the bend region (10). The guide member (2) in accordance with the present disclosure, provides sufficient support to the cable (1) without forming holes on the chassis to clamp the cable (1) during cable routing operation. The over-molding structure (2) may be manufactured from any molding techniques and facilitate orientation of the cable (1) in a predefined position.
[038] The guide member (2) of the cable may also be provided at different meeting junctures of the cable (1) to connect two or more portions of the cable (1) and/or to connect multiple cables with one another. The guide member (2) is not required to cover the entire length of the cable (1), rather the guide member (2) is provided only at the bend regions (10) of the cable (1). The guide member (2) comprises at least two slots (2a) formed on an outer surface of the guide member (2), as shown in FIG. 1. The guide member (2) is formed on the cable (1), such that an inner surface of the guide member (2) abuts against an outer surface of the cable (1). The molding of the guide member (2) is done on the insulator layer (12) at the bend regions (10) of the cable (1). In an exemplary embodiment, an injection molding is performed on the bend regions (10) of the cable (1) to integrally form the guide member (2). The cable (1) routed in any angular orientation is supported from the guide member (2) in the predefined orientation or position. In an exemplary embodiment, the 90 deg. swiveling of the cable (1) is supported by the guide member (2) without requirement of any dedicated clamping means. The guide member (2) also reduces effects of movement and vibration on the cable (1). The guide member (2) prevents breakage or cracking of cable (1) due to vibrations of the vehicle after a prolonged time period.
[039] Referring to FIG. 3 and FIG. 4, a routing of the cable (1) to connect a power source (5) for example, battery to an isolator switch (6) is depicted. The power source (5) and the isolator switch (6) are preferably mounted on front chassis or frame of the vehicle or preferably under a bonnet of the vehicle. The power source (5) comprises a positive terminal and a negative terminal, such that the positive terminal is configured to allow flow of charge particles or current from the power source (5) to the isolator switch (6) and/or to other electronic components of the vehicle. The negative terminal is connected to chassis

or frame of the vehicle, acting as ground terminal to complete the electric circuit. The cable (1) with the guide member (2) is configured to connect all the electronic components present in the vehicle with each other or with the power source (5) of the vehicle. In an exemplary embodiment, the cable (1) with the guide member (2) is configured to connect the power source (5) with the isolator switch (6) of the vehicle.
[040] The cable (1) is defined with a first end (101), a second end (102) and an intermediate portion (103), as shown in FIG. 3. The intermediate portion (103) is defined between the first end (101) and the second end (102) of the cable (1). Each end (101, 102) of the cable (1) is crimped to expose the plurality of wires (11), such that first end (101) of the cable (1) is connected with a first terminal connector (3), and the second end (102) of the cable (1) is connected with a second terminal connector (4). In an exemplary embodiment, the first terminal connector (3) is configured to connect the cable (1) with the power source (5) of the vehicle. The second terminal connector (4) is configured to connect the cable (1) with the isolator switch (6) of the vehicle, as sown in FIG. 4. The cable (1) routed between the isolator switch (6) and the power source (5) defined as the intermediate portion (103) of the cable (1) comprises the plurality of bend regions (10), such that each bend region (10) is fixed with the guide member (2) to provide support to the cable (1). The guide member (2) is fixed at bend regions (10) of the cable (1) only and do not require any additional clamping means to provide support to the cable (1) thereof. The guide member (2) itself provides sufficient support and stiffness to the cable (1) during routing of the cable (1) along the chassis or frame of the vehicle. The guide member (2) for the cable (1) comprises an over-mold structure formed on an insulator layer (12) of the cable (1) and at each of plurality of bend regions (10).
[041] In an exemplary embodiment, a method for manufacturing a cable routing structure (100) for a vehicle is disclosed. The method comprises: measuring and cutting predetermined length of the cable (1) required to connect a power source (5) with an isolator switch (6); crimping first end (101) and second end (102) of the cable (1) to facilitate mounting of a first terminal connector (3) and a second terminal connector (4) respectively; marking the cable (1) such that the marking indicates plurality of bend regions

(10) of the cable (1); placing the cable (1) with the marking inside a mold to facilitate molding of a guide member (2) on an outer surface of the cable (1) and in between the markings thereof; and inspecting the cable (1) formed with the guide member (2) at the respective bend regions (10) of the cable (1).
[042] The cable routing structure in accordance with the present disclosure comprises a cable fitted with an guide member to provide sufficient support to the cable at different bend regions of the cable.
[043] The guide member in accordance with the present disclosure, if fixed with the cable outer surface only at the bend region and do not cover the entire cable. Thus, the guide member reduces cost as well as assembling time of the cables.
[044] The guide member provides sufficient support and stiffness to the cable at each bend regions of the cable during routing of the cable. The utilization of the guide member avoids implementation of clamping means such as clips to fix the cables with the chassis or frame of the vehicle.
[045] The over-molding of material around an insulating layer of cable/wire provides sufficient stiffness to the cable when the cable is bend during routing.
[046] The cables provided with only guide member to provide sufficient support to the cables also reduces assembling cost as well as assembling time of the cables to the vehicle, which in turn reduces manufacturing cost of the vehicle.
Equivalents:
[047] The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended

merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[048] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
[049] Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
[050] The use of the expression "at least" or "at least one" suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
[051] Any discussion of documents, acts, materials, devices, articles and the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.

[052] The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
[053] While considerable emphasis has been placed herein on the particular features of this disclosure, it will be appreciated that various modifications can be made, and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other modifications in the nature of the disclosure or the preferred embodiments will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.

List of Reference Numerals:

Cable routing structure 100
Bend region 10
Cable 1
First end of cable 101
Second end of cable 102
Intermediate portion of cable 103
Wires 11
Insulator layer 12
Guide member 2
Slots 2a
First terminal connector 3
Second terminal connector 4
Power source 5
Isolator switch 6

We Claim:
1. A cable routing structure (100) for a vehicle, the structure (100) comprising:
a cable (1) having a first end (101), a second end (102) and an intermediate portion (103), wherein the intermediate portion (103) is defined between the first end (101) and the second end (102);
the intermediate portion (103) comprises plurality of bend regions (10) to facilitate routing of the cable (1) within the vehicle;
each of the plurality of bend regions (10) is encapsulated with a guide member (2), wherein the guide member (2) provides support to the cable (1) during routing of the cable (1) for connecting electronic components of the vehicle.
2. The cable routing structure (100) as claimed in claim 1, wherein an inner surface of the guide member (2) abuts with an outer surface of the cable (1).
3. The cable routing structure (100) as claimed in claim 1, wherein the guide member (2) is formed from a composite material having polypropylene and through a molding process.
4. The cable routing structure (100) as claimed in claim 1, wherein the guide member (2) comprises at least two slots (2a) formed on an outer surface of the guide member (2).
5. The cable routing structure (100) as claimed in claim 1, wherein the cable (1) comprises a plurality of wires (11) enclosed by an insulator layer (12) along length of the plurality of wires (11), wherein the cable (1) is configured to connect a power source (5) with an isolator switch (6) of the vehicle.
6. The cable routing structure (100) as claimed in claim 1, wherein molding of the guide member (2) is done on the insulator layer (12) at the bend regions (10) of the cable (1).

7. The cable routing structure (100) as claimed in claim 1, wherein the first end (101) of the cable (1) is connected with a first terminal connector (3), wherein the first terminal connector is configured to connect the cable (1) with the power source (5) of the vehicle.
8. The cable routing structure (100) as claimed in claim 1, wherein the second end (102) is connected with a second terminal connector (4), wherein the second terminal connector (4) is configured to connect the cable (1) with the isolator switch (6) of the vehicle.
9. A method for manufacturing a cable routing structure (100) for a vehicle, the method comprises:
marking a cable (1) connecting a power source (5) with an isolator switch (6) of the vehicle, such that the marking indicates plurality of bend region (10) of the cable (1);
placing the cable (1) with the markings inside a mold to facilitate molding of a guide member (2) on an outer surface of the cable (1) and in between the markings thereof; and
inspecting the cable (1) formed with the guide member (2) at the respective bend regions (10) of the cable (1).
10. A guide member (2) for a cable (1), wherein the guide member (2) comprises an over-
mold structure formed on an insulator layer (12) of the cable (1) and at each of plurality of
bend regions (10) by a molding process.