Hybrid Component Installation Using Cooling System as Collision Protector
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Solution Overview
Problem
In hybrid vehicles, the electric energy storage device poses a risk of damage and fire during collisions, potentially causing injury and vehicle damage due to its location on the longitudinal frame rail, which can lead to substantial forces being applied to the frame rail, causing damage.
Innovation Solution
The electric energy storage device is positioned adjacent to the external surface of the frame rail, with a cooling system unit, including a radiator, placed externally to provide cooling and act as a physical protector, forming a deformation zone that absorbs kinetic energy during collisions, thereby reducing the risk of damage to the energy storage device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the electric energy storage device is mounted on the longitudinal frame rail, then it is easily accessible and integrated into the vehicle structure, but it is vulnerable to damage during collisions due to substantial forces applied to the frame rail
Solution Approach 1:
A second unit containing cooling system components (radiator, fan, pump) is positioned between the external environment and the electric energy storage device. This intermediary unit absorbs collision forces and protects the battery from direct impact while maintaining cooling functionality.
Solution Approach 2:
The cooling system components, particularly the radiator and fan assembly, are strategically positioned to create a deformation zone that absorbs kinetic energy before it reaches the electric energy storage device during potential collisions.
2Reliability
If the electric energy storage device is positioned away from the frame rail to reduce collision damage, then protection improves, but structural integration and stability are compromised
Solution Approach 1:
The electric energy storage device is nested within the vehicle's frame structure, with the battery unit positioned in the first unit adjacent to the frame rail. The cooling system components are nested in the second unit that partially surrounds and protects the battery while maintaining structural integration.
3Temperature
If a cooling system is added to cool the electric energy storage device and power electronics, then thermal management is improved, but the complexity of the installation increases
Solution Approach 1:
The cooling system is merged with the existing hybrid vehicle installation structure. The radiator, fan, and pump are integrated into the second unit that also serves as a protective structure, combining thermal management and structural protection functions into a single integrated assembly.
Solution Approach 2:
The second unit containing the cooling system components serves multiple functions: it provides thermal management for the battery and power electronics, acts as a protective barrier during collisions, and maintains structural integration with the vehicle frame. This multi-functionality reduces overall system complexity.
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 reduces the risk of damage to the electric energy storage device during collisions by creating a deformation zone that absorbs kinetic energy, minimizing the risk of personal injury and vehicle damage while maintaining effective cooling for the device.
Implementation Method 1
a cooling system with at least one heat exchanger
Implementation Method 2
A radiator in a cooling system usually consists of conduits that are heat transferring components
Implementation Method 3
a deformation zone is formed in front of the first unit and the electric energy storage device, wherein a great part of the kinetic energy at a collision may be eliminated
Data Source
Figure 1~2
Figure 3~4
AI summary
The present invention relates to an installation of hybrid components in a vehicle (1) comprising a frame rail (4) with an extension the longitudinal direction of the vehicle. The installation comprises a first unit (7), comprising an electric energy storage device (7b), a second unit (8) comprising at least one component (8b-e) in a cooling system, and fastening elements (10) with which the first unit (7) and the second unit (8) may be attached on the frame rail (4). The first unit (7) is attached in a position adjoining a side surface (4a) of the frame rail (4), and the second hybrid component (8) is attached at a greater distance from the frame rail (4) and in a position at least partly outside of the first unit (7).