High-Voltage Module Bracket Structure for Front Impact Protection
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Solution Overview
Problem
Large power converters used in vehicles to increase motor output torque protrude forward, exposing them to impact loads without adequate protection, and limit space for impact-absorbing members, making them vulnerable to damage in collisions.
Innovation Solution
A protective structure for high-voltage modules, comprising a case with side and front walls, a bracket positioned forward to receive impact loads, and connecting portions that distribute the load to more rigid areas, reducing damage to the module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large power converter is used to increase motor output torque, then the electrical resistance is reduced and durability is improved, but the power converter protrudes forward and becomes vulnerable to impact loads
Solution Approach 1:
The patent introduces an energy absorbing member as an intermediary protective structure between the external environment and the power converter. This member absorbs impact loads from collisions and transmits reduced loads to the power converter, thereby protecting the vulnerable component while maintaining its large size for improved reliability
Solution Approach 2:
The energy absorbing member is positioned in advance before the power converter in the impact direction, creating a cushioning layer that absorbs impact energy before it reaches the power converter. This prior cushioning prevents direct impact on the vulnerable component
2Loss of energy
If a large power converter is used to reduce electrical resistance, then power conversion efficiency is improved, but space for mounting energy absorbing members is limited
Solution Approach 1:
The patent utilizes the vehicle width direction as an additional dimension to position the energy absorbing member. By extending the protective member laterally beyond the power converter's width, sufficient mounting space is created without increasing the frontward projection that would worsen impact vulnerability
3Productivity
If the power converter is positioned forward to reduce electrical resistance, then power conversion performance is improved, but no protective member can be positioned forward of it
Solution Approach 1:
The energy absorbing member serves multiple functions: it acts as a protective barrier against impact loads, provides structural support, and can be designed to integrate with the vehicle's front bumper structure. This multi-functionality allows protection without compromising power conversion performance
Data Source
AI summary
In a protective structure for a high-voltage module configured to convert electric power that is transferred between a motor serving as a driving force source and a power supply, the high-voltage module is housed in a case. The case includes side walls located on both sides of the case in the vehicle width direction and a front wall located on the front side of the case in the direction of travel of the vehicle. The front wall includes a middle portion that is a middle portion of the front wall in the vehicle width direction and connecting portions located at both ends of the front wall in the vehicle width direction. The connecting portions are located rearward of the middle portion. The protective structure includes a bracket disposed at a predetermined distance forward of the middle portion. Both ends of the bracket are connected to the connecting portions.