Fuel Cell Power Distribution Layout for Collision-Protected HV Cables
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Solution Overview
Problem
In fuel cell vehicles, high-voltage components are at risk of damage during collisions, leading to potential electrical fires due to their positioning behind the power distribution unit, which can cause them to be sandwiched between the unit and the dash panel.
Innovation Solution
The fuel cell module design includes a power distribution unit with a concave portion positioned closer to the rear surface, allowing connectors and cables to be securely connected on the side surfaces, reducing the risk of damage and fire by preventing them from being sandwiched during collisions, and incorporating an impact-absorbing part to protect the cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If high-voltage parts are disposed behind the power distribution unit, then the power distribution unit can be compactly designed, but the high-voltage parts may be sandwiched between the power distribution unit and dash panel during collision causing damage and fire
Solution Approach 1:
The patent relocates connectors and cables from the rear surface (one-dimensional positioning) to the side surfaces of the power distribution unit. This dimensional change in positioning prevents the high-voltage parts from being sandwiched between the power distribution unit and dash panel during collision, thereby resolving the safety issue while maintaining compact design.
Solution Approach 2:
The patent creates a concave portion specifically at the rear surface of the power distribution unit to provide localized protection for the connectors and cables. This local structural modification allows the high-voltage parts to be positioned in a protected zone that prevents sandwiching during collision, addressing the safety concern without compromising overall design compactness.
2Ease of manufacture
If connectors and cables are positioned on the rear surface of the power distribution unit, then connection is simplified, but they are vulnerable to damage during vehicle collision
Solution Approach 1:
The patent moves connectors and cables from the rear surface to the side surfaces of the power distribution unit. This positional change in a different dimension (from rear to side) eliminates the vulnerability to sandwiching during collision while maintaining ease of connection through the side surface mounting approach.
Solution Approach 2:
The patent extracts the connectors and cables from the vulnerable rear surface location and relocates them to the side surfaces. This extraction from the harmful zone (rear surface between unit and dash panel) removes the collision damage risk while preserving the connection functionality.
3Ease of manufacture
If the power distribution unit is designed without a concave portion, then manufacturing is simpler, but connectors and cables cannot be protected from collision impact
Solution Approach 1:
The patent introduces a concave portion as a localized structural feature on the rear surface of the power distribution unit. This local modification provides protective positioning for connectors and cables without significantly complicating the overall manufacturing process, as it is simply a recessed area rather than a complex structural change.
Solution Approach 2:
The concave portion is pre-formed in the power distribution unit during manufacturing, creating a protective structure in advance before assembly. This preliminary structural preparation ensures that connectors and cables will be positioned in a protected zone, preventing collision damage before the vehicle is put into service.
Data Source
AI summary
An embodiment fuel cell module includes a fuel cell, a power distribution unit disposed above the fuel cell, the power distribution unit including a concave portion, and a cable configured to be connected to a connector of the power distribution unit within the concave portion. The power distribution unit according to an embodiment includes a front surface, a rear surface located opposite the front surface in a first direction, and first and second side surfaces facing each other in a vehicle width direction between the front surface and the rear surface, the vehicle width direction being a direction intersecting the first direction. In an embodiment, the connector is disposed on the first side surface or the second side surface to be connected to the cable.