Cooling Module Bracket With Break-Away Arm for Frontal Crash Protection

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Solution Overview

Problem

Existing cooling modules in vehicle front end structures are prone to damage during low-speed frontal impact crashes, leading to costly repairs and potential inability to drive the vehicle.

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 and reducing damage.

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 during frontal impact crashes

Engineering Contradiction:

Improvecooling module securityVSAvoidcrash damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The bracket is divided into two distinct arms: a rigid arm for secure connection and a break-away arm for crash protection. This segmentation allows different parts of the same component to have different mechanical properties, enabling the bracket to provide both secure mounting and crash protection functions simultaneously.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The bracket changes its structural parameters during a crash event. The break-away arm transitions from a connected state to a broken state, changing the bracket's rigidity from high to low. This parameter change allows the system to adapt to different operational conditions: rigid during normal operation, flexible during crashes.

Inventive Principle:

Principle #35Parameter changes

2Object-affected harmful factors

If a break-away mechanism is added to protect the cooling module, then crash damage is reduced, but the device complexity increases

Engineering Contradiction:

Improvecrash damageVSAvoidbracket structure

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 mounting function and the crash protection function into a single unified component, thereby reducing overall system complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The break-away arm is designed as a sacrificial component that is intended to fail during a crash. It is made from less expensive materials and with simpler construction compared to the rigid arm, as it serves as a disposable element that protects more expensive components like the cooling module.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Strength

If the rigid arm is made stronger to prevent breakage, then the cooling module connection is more stable, but the break-away mechanism cannot function during crashes

Engineering Contradiction:

Improverigid arm strengthVSAvoidbreak-away function

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

Different parts of the bracket have different quality characteristics. The rigid arm is designed with high strength and rigidity to maintain stable connection, while the break-away arm is designed with lower strength to fail during crashes. This local differentiation of material properties and structural characteristics allows each component to fulfill its specific function optimally.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS12296888B2Cooling module support bracket

Publication Date: 2025.05.13 VOLVO CAR CORP

AI summary

A bracket for a cooling module in a front end structure of a vehicle includes forward crash-box connection means, cooling module connection means, a rigid arm extending between the forward crash-box connection means at a forward side and the cooling module connection means at a rearward side; rear crash-box connection means; and a break-away arm extending from the rearward side of the rigid arm and the rear crash-box connection means.