Dual-Layer High-Voltage Cable Protection for Vehicle Collisions
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Solution Overview
Problem
Current high-voltage cable protection structures for vehicles are inadequate in performance and costly, particularly in preventing damage during collisions.
Innovation Solution
A dual protection system comprising a resin-based first protection member for normal conditions and a metal-based second protection member with higher rigidity, covering a narrower range, is implemented to enhance collision protection while minimizing material and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single protection member covers the entire high-voltage cable, then the cable is protected along its full length, but the cost and mass increase
Solution Approach 1:
The protection structure is divided into two distinct protection members: a first protection member made of resin material that covers a larger range, and a second protection member made of metal material with higher rigidity that covers a narrower, critical range. This segmentation allows each component to be optimized for its specific function and location, reducing overall mass while maintaining protection performance.
Solution Approach 2:
The second protection member with higher rigidity is strategically placed at the location where the high-voltage cable is most vulnerable to impact during vehicle collision. This local quality approach concentrates protective resources where they are most needed, rather than uniformly protecting the entire cable length, thereby reducing total material usage and cost.
2Reliability
If a highly rigid protection member covers the entire cable, then collision protection is improved, but the material cost increases
Solution Approach 1:
The high-rigidity metal second protection member is applied only to the critical section of the cable where impact damage is most likely to occur during collision, rather than covering the entire cable length. This localized application of high-rigidity material significantly reduces material cost while maintaining effective collision protection at the vulnerability point.
Solution Approach 2:
The protection structure uses a composite approach combining two different materials: resin for the first protection member and metal for the second protection member. Each material is selected for its appropriate properties and applied in the optimal location, creating a cost-effective composite protection system that balances performance and material cost.
3Ease of manufacture
If only a resin protection member is used, then the cost is low, but the protection performance during collision is insufficient
Solution Approach 1:
The protection structure combines resin material for the first protection member with metal material for the second protection member. The resin provides baseline protection and cost-effectiveness, while the metal second protection member adds the necessary rigidity and strength for collision protection at the critical location, achieving a balance between cost and performance.
Solution Approach 2:
The protection function is segmented between two materials with different properties: resin for general protection and metal for enhanced collision resistance. This segmentation allows the system to achieve adequate collision protection performance without using expensive metal material throughout the entire cable length, thus controlling costs.
Data Source
AI summary
The high-voltage cable protection structure of the present disclosure is a high-voltage cable protection structure that protects a high-voltage cable extending from an electrical device mounted in a front compartment of a vehicle to the rear of the vehicle. Also, in the front compartment, rear parts are arranged behind the electrical device in a vehicle front-rear direction, and a first protection member that covers the high-voltage cable, and a second protection member that is more rigid than the first protection member and that is arranged to cover the high-voltage cable outside the first protection member in a narrower area than the first protection member are included.