Cooling Module Support Bracket That Releases in Frontal Collisions

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Solution Overview

Problem

The front end structure of vehicles is prone to damage in frontal impact crashes, which can cause costly repairs and render the vehicle undrivable due to damage to the cooling module and fan, even in low-speed collisions.

Innovation Solution

A bracket system for the cooling module that includes forward and rear crash-box connection means, a rigid arm, and a break-away arm, allowing the cooling module to move rearward during a collision, thereby minimizing damage and enabling the vehicle to remain operational.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the cooling module is rigidly connected to the front end structure, then the cooling module is securely positioned during normal operation, but the cooling module is damaged in frontal impact crashes

Engineering Contradiction:

Improvesecure positioning of cooling moduleVSAvoiddamage to cooling module in collision

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The bracket is divided into two distinct arms: a rigid arm that provides stable positioning during normal operation, and a break-away arm that is designed to fracture under collision forces. This segmentation allows the bracket to provide both secure positioning and collision protection, resolving the contradiction between reliability and damage resistance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The break-away arm is designed with specific geometric parameters (reduced cross-section, optimized length) that change its mechanical properties. These parameter changes enable the arm to have sufficient strength for normal operation but become intentionally weak to break away during collisions, protecting the cooling module from damage.

Inventive Principle:

Principle #35Parameter changes

2Object-affected harmful factors

If a break-away mechanism is added to protect the cooling module, then damage in collision is reduced, but the bracket structure becomes more complex

Engineering Contradiction:

Improvedamage reduction in collisionVSAvoidbracket structure complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The break-away mechanism is merged into the bracket structure itself rather than being a separate system. The break-away arm is an integral part of the bracket, combining the positioning function and the protection function into a single unified structure, thereby minimizing added complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The break-away arm is designed to be a sacrificial component that is discarded (broken) during collision to protect the more valuable cooling module. This intentional discarding of a simple, inexpensive component achieves protection without requiring complex recovery or replacement systems.

Inventive Principle:

Principle #34Discarding and recovering

Data Source

PatentEP4159511B1Cooling module support bracket

Publication Date: 2024.11.06 VOLVO CAR CORP

Figure 1A~1B
Figure 1C~1D
Figure 2A~2B

AI summary

A bracket (10) for a cooling module in a front end structure of a vehicle includes forward crash-box connection means (16), cooling module connection means (18), a rigid arm (20) extending between the forward crash-box connection means (16) at a forward side and the cooling module connection means (18) at a rearward side; rear crash-box connection means (26); and a break-away arm (28) extending from the rearward side of the rigid arm (20) to the rear crash-box connection means (26).