Deformable Housing Connecting Portion for Energy Module Crash Protection
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Solution Overview
Problem
Conventional devices for accommodating energy modules in motor vehicles are heavy due to rigid metal housings, which decrease vehicle performance and increase energy needs, while also failing to effectively absorb external forces during accidents without risking damage to the modules.
Innovation Solution
A device with a housing featuring a connecting portion that deforms under predetermined forces, allowing accommodating portions to move relative to each other, thereby absorbing crash loads while maintaining module sealing and protection, using materials like polypropylene for the connecting portion and fiber-reinforced polyamide for the accommodating portions, and a releasable clamp mechanism for controlled deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid metal housing is used to protect energy modules, then the protective function is improved, but the weight of the device increases significantly
Solution Approach 1:
The housing is divided into multiple accommodating portions (first accommodating portion, second accommodating portion, third accommodating portion) that can move relative to each other during deformation, allowing the structure to absorb energy through controlled movement rather than relying entirely on rigid material strength
Solution Approach 2:
The connecting portion is designed with specific deformation characteristics that allow it to change shape under predetermined forces, transforming the housing from a purely rigid structure to one that can dynamically adjust its mechanical properties during impact events
2Force
If a rigid metal housing is used to absorb external forces, then the force absorption capability is improved, but the device weight increases
Solution Approach 1:
The housing transitions from a static rigid structure to a dynamic system where the connecting portion can deform and allowing accommodating portions to move relative to each other during impact, enabling energy absorption through controlled kinetic movement rather than purely elastic deformation of heavy metal
Solution Approach 2:
By segmenting the housing into multiple movable accommodating portions connected by deformable connecting portions, the structure can absorb energy through the relative movement and deformation of segments, reducing the need for heavy continuous metal structures
3Weight of stationary object
If the housing is made lighter using lighter materials, then the device weight is reduced, but the protective capability may be compromised
Solution Approach 1:
The connecting portion is designed with specific deformation parameters that allow it to absorb energy through controlled deformation, compensating for the reduced material strength of lighter materials by using geometric and structural design to achieve the required protective performance
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution reduces the weight of the device, absorbs crash forces effectively, minimizes the risk of module damage and electrolyte leakage, and allows for the use of lighter materials, thereby enhancing vehicle performance and safety.
Implementation Method 1
the connecting portion allows the first and second accommodating portions to move relative to one another in a predetermined manner as a result of the deformation
Implementation Method 2
seals arranged between the housing base and the housing cover are provided which also prevent the leakage of an electrolyte, which is present in the energy module, out of the housing
Data Source
AI summary
A device is provided for accommodating at least one energy module for a motor vehicle, in particular for accommodating at least one high-voltage energy module for a hybrid or electric vehicle. The device includes a housing having a first and a second accommodating portion for accommodating at least one energy module, and a connecting portion arranged between the first and the second accommodating portions. The connecting portion is designed such that, when the housing is subjected to a predetermined force, deformation being the result, the connecting portion allows the first and the second accommodating portions to move relative to one another in a predetermined manner as a result of the deformation.