Deformation Section Energy Module Retainer for Crash Load Absorption
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Solution Overview
Problem
Conventional devices for holding energy modules in motor vehicles, particularly high-voltage modules for hybrid or electric vehicles, are heavy due to inefficient power transmission pathways, leading to reduced vehicle performance and increased energy requirements, and have complex assembly processes resulting in high costs.
Innovation Solution
A device with a holding element that includes a deformation section to absorb crash loads and external forces, allowing relative movement between the energy module and attachment points, and a housing that surrounds the holding element for protection and sealing, optimizing the structure for reduced weight and improved assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fixed housings are used to hold energy modules, then the housing can absorb all forces acting on the energy modules and protect them, but the housing weight increases due to dimensioning for full load bearing
Solution Approach 1:
The device is segmented into a load-bearing holding element and a non-load-bearing housing. The holding element absorbs crash forces and holds the energy modules, while the housing provides only protective enclosure and sealing. This segmentation allows the housing to be optimized for protection without the weight penalty of being designed to bear all loads.
Solution Approach 2:
The holding element incorporates deformation sections that are designed to deform in a controlled manner during crashes to absorb forces. This dynamic behavior allows the system to manage crash forces actively rather than relying on a statically over-engineered housing.
2Weight of stationary object
If power transmission pathways are optimized for shortest route, then device weight is reduced, but structural integrity and force absorption may be compromised
Solution Approach 1:
The device separates the force absorption function (held by the holding element with deformation sections) from the protective enclosure function (performed by the housing). This allows power transmission pathways to be optimized for shortest route and reduced weight while the holding element maintains structural integrity and force absorption capability.
3Reliability
If complex wiring and piping are used within the housing, then energy modules can be protected, but assembly time and costs increase due to limited access
Solution Approach 1:
The holding element is designed as a separate, modular component that can be assembled with the energy modules outside the housing. This modular approach allows wiring and piping to be accessed and connected more easily during assembly, reducing assembly time and costs while maintaining the protective function of the housing.
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 overall weight of the device by optimizing force absorption and transmission, enhances protection of energy modules during accidents, and simplifies assembly by improving accessibility and reducing assembly time.
Implementation Method 1
the deformation section, when a predetermined force is applied to the holding element with deformation, preferably plastic deformation, causes a predetermined relative movement resulting from the deformation between the at least one energy module holding holding portion and the one or more attachment portions of the holding member allows
Data Source
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AI summary
The invention relates to a device for retaining at least one energy module for a motor vehicle, in particular for retaining at least one high-voltage energy module for a hybrid or electric vehicle, wherein the device has a retaining element which can be fitted on the vehicle body via one or more fitting portions and is intended for retaining the at least one energy module, wherein the retaining element has at least one retaining portion, for retaining the at least one energy module, and at least one deformation portion. The invention provides for the deformation portion to be configured such that, when a predetermined force is applied to the retaining element, the deformation portion, while being deformed, allows predetermined relative movement, resulting from the deformation, between the retaining portion, which retains the at least one energy module, and the one or more fitting portions of the retaining element. The invention also relates to a vehicle having such a device, and to a corresponding installation method.