Cooling Module Mounting Bracket for Crash Breakaway and Vibration

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Solution Overview

Problem

Existing vehicle cooling module mounting systems are incompatible with certain vehicle architectures, reduce the heat treatment performance due to bulk, and are prone to damage and displacement during crashes, leading to costly repairs.

Innovation Solution

A fastening system comprising a support with cavities for a connecting block and filter element, a mounting bracket with a load-bearing member, and a clip-type fastening mechanism that decouples the cooling module from the support, allowing it to absorb vibrational stresses and break away upon impact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If vertically extending pins with tabs are used to secure the cooling module, then the module can be mounted on the support, but significant transverse bulk is generated reducing the heat treatment performance

Engineering Contradiction:

Improvemounting securityVSAvoidheat exchange surface

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The mounting system is divided into separate functional elements: a connecting block integrated with the cooling module, a separate mounting bracket attached to the support, and a fastening mechanism linking them. This segmentation eliminates the need for bulky tabs extending from pins, allowing the cooling module to maintain its compact form and maximize heat exchange surface area while still achieving secure mounting through the distributed fastening points.

Inventive Principle:

Principle #1Segmentation

2Object-affected harmful factors

If pins are configured to subject to fusibility stresses so they break upon impact, then crash safety requirements are met, but significant and costly damage occurs to the cooling module

Engineering Contradiction:

Improvecrash protectionVSAvoidrepair cost

Core Design Contradiction:

Object-affected harmful factorsVSEase of repair

Solution Approach 1:

The mounting bracket is designed as a sacrificial component that breaks away during frontal crashes, protecting the expensive cooling module. The bracket is positioned and dimensioned to fail first, absorbing the impact energy while the connecting block and cooling module remain intact. This allows the bracket to be replaced inexpensively while avoiding costly damage to the cooling module itself.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The mounting bracket serves as an intermediary element between the support and the cooling module's connecting block. It is specifically designed to be the weak link in the chain during crash events, breaking away to protect the more valuable cooling module. This intermediary function allows the system to meet crash safety requirements while minimizing damage to the cooling module.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of repair

If a removable mounting bracket is used, then repair costs are reduced, but the system complexity increases with multiple components

Engineering Contradiction:

Improverepair costVSAvoidmounting system structure

Core Design Contradiction:

Ease of repairVSDevice complexity

Solution Approach 1:

The connecting block is merged with the cooling module as an integrated component, eliminating the need for separate mounting ears or tabs. The mounting bracket is designed to cooperate with this integrated connecting block through a standardized fastening mechanism. This merging reduces the total number of parts compared to traditional pin-and-tab systems while maintaining the ability to replace only the bracket for repairs.

Inventive Principle:

Principle #5Merging (Combining)

4Stability of the object's composition

If the cooling module is securely fixed to prevent displacement, then mounting stability is improved, but the module cannot absorb vibrational stresses effectively

Engineering Contradiction:

Improvemounting stabilityVSAvoidvibration stress

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The mounting system transitions from a rigid fixed connection to a dynamic system that can adapt to vibrational stresses. The separate mounting bracket and fastening mechanism allow for controlled movement and stress distribution, enabling the cooling module to absorb vibrational energies while maintaining stable mounting during normal operation.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentEP4407154B1System for attaching a cooling module of a vehicle

Publication Date: 2026.03.11 RENAULT SA

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AI summary

Mounting system (3) for a vehicle cooling module comprising a support (4), a connecting stud (5), a filter element (6) configured to surround the connecting stud (5), a removable mounting tab (7) configured to cooperate with the filter element (6) and comprising a mounting element (73) and a load-bearing element (74), the support (4) comprising a first cavity and a second cavity, respectively configured to cooperate with the filter element (6) and the load-bearing element (74).