EV Inverter Bracket Shell Structure for Side-Collision Protection
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Solution Overview
Problem
In hybrid vehicles, high-voltage components such as the inverter and converter are vulnerable to damage during lateral collisions due to deformation of the floor panel and potential shearing of attachment bolts, which can lead to the components being crushed or falling.
Innovation Solution
The arrangement of high-voltage components between the vehicle structure and floor side frames, surrounded by an outer shell structure constructed from an attachment bracket that stretches to absorb collision forces, preventing the components from being crushed and maintaining the integrity of the attachment bolts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If high-voltage components are arranged between the floor side frame and tunnel side frame, then space utilization is improved, but vulnerability to lateral collision damage increases
Solution Approach 1:
A cushioning member is provided between the high-voltage component and the floor side frame to absorb collision forces before they reach the component. This beforehand cushioning prevents direct impact damage during lateral collisions while maintaining the compact arrangement of the high-voltage component in the limited space between the floor side frame and tunnel side frame.
Solution Approach 2:
The cushioning member acts as an intermediary element between the high-voltage component and the floor side frame. During lateral collision, this intermediary absorbs and dissipates the impact force, preventing the transmission of harmful forces to the high-voltage component while allowing the component to remain in its space-efficient position.
2Stability of the object's composition
If the attachment bracket is made rigid to secure the high-voltage component, then component stability is improved, but the bracket may be crushed during lateral collision
Solution Approach 1:
The attachment bracket is designed with specific structural parameters including thickness, material properties, and geometric configuration that allow it to maintain rigidity for securing the high-voltage component while also having sufficient ductility to deform and absorb collision forces without crushing. The bracket's parameters are optimized to balance stability and collision resistance.
Solution Approach 2:
The attachment bracket is constructed using composite material structures or materials with combined properties that provide both the rigidity needed to securely hold the high-voltage component and the toughness required to resist crushing during lateral collisions. This composite approach allows the bracket to exhibit both stability and collision resistance.
3Length of stationary object
If the high-voltage component is positioned closer to the floor panel to reduce height, then vehicle height is reduced, but the component becomes more vulnerable to deformation during collision
Solution Approach 1:
The cushioning member is positioned between the high-voltage component and the floor side frame to provide beforehand protection against collision forces. This allows the component to be positioned closer to the floor panel for reduced vehicle height while the cushioning member absorbs impact forces that would otherwise cause deformation during lateral collisions.
Solution Approach 2:
The cushioning member serves as an intermediary protective layer that enables the high-voltage component to be positioned in the space-efficient location closer to the floor panel. During collision, this intermediary absorbs and dissipates forces, preventing deformation of the component while maintaining the reduced vehicle height configuration.
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
This configuration effectively protects high-voltage components from lateral collisions by distributing collision forces and preventing the attachment bracket from being crushed, thereby ensuring the components remain secure and functional.
Implementation Method 1
since the outer shell structure is constructed of the attachment bracket, the attachment bracket can be stretched against these pressing forces. Thus, the attachment bracket can be prevented from being crushed
Data Source
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AI summary
The disclosed technique relates to a lower structure of an electric vehicle. The lower structure of the electric vehicle includes: an AT transmission provided below a floor panel and in an intermediate portion in a right-left direction thereof; an inverter arranged between the AT transmission and a floor side frame; and an attachment bracket for attaching the inverter to the floor panel. The attachment bracket has an outer shell structure including: an inner wall portion dividing the inverter and the AT transmission; an outer wall portion dividing the inverter and the floor side frame; an upper wall portion; and a lower wall portion.