Vehicle Front Structure With Inverter Guide for Brake Booster Deflection

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Solution Overview

Problem

During a vehicle frontal collision, the power converter and auxiliary machines like the brake booster can move rearward, potentially colliding and causing damage, which may lead to further rearward movement and endanger occupants.

Innovation Solution

A vehicle front structure with a power converter and auxiliary machine is designed to include a guide member with an inclined surface that abuts the auxiliary machine during a collision, displacing it upward to prevent rearward movement and protect the power converter and occupants.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If the power converter is arranged on top of the travel motor to improve space efficiency, then the loss of electric power is reduced, but the power converter may move rearward during frontal collision and collide with the auxiliary machine, causing damage

Engineering Contradiction:

Improveloss of electric powerVSAvoidcollision damage to power converter

Core Design Contradiction:

Loss of energyVSObject-affected harmful factors

Solution Approach 1:

A guide member is introduced as an intermediary component between the power converter and auxiliary machine. The guide member includes an inclined surface that guides the auxiliary machine to move upward when the power converter moves rearward during collision, preventing direct collision damage while maintaining the space-efficient arrangement of the power converter on top of the travel motor

Inventive Principle:

Principle #24Intermediary (Mediator)

2Volume of moving object

If the power converter and auxiliary machine are arranged close together to improve space utilization, then the compartment space is efficiently used, but the auxiliary machine may move further rearward with the dashboard and enter the cabin during collision, endangering occupants

Engineering Contradiction:

Improvecompartment space utilizationVSAvoidoccupant safety hazard

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The guide member acts as a mediator that intercepts the rearward movement of the auxiliary machine. By providing an inclined surface, it converts the rearward movement force into upward movement, preventing the auxiliary machine from entering the cabin and thus protecting occupants while maintaining efficient space utilization

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If a protector is added to the power converter to prevent damage during collision, then the power converter is protected, but the auxiliary machine may still move rearward and enter the cabin, endangering occupants

Engineering Contradiction:

Improvepower converter protectionVSAvoidoccupant safety hazard from auxiliary machine movement

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The guide member is positioned to interact with the auxiliary machine directly, serving as a mediator that controls the movement path of the auxiliary machine. The inclined surface of the guide member redirects the auxiliary machine's rearward movement into upward movement, preventing cabin intrusion while the protector on the power converter handles the protection of the power converter itself

Inventive Principle:

Principle #24Intermediary (Mediator)

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

The solution effectively prevents the auxiliary machine from moving rearward, reducing the risk of damage to the power converter and enhancing occupant safety by distributing collision loads to the drive system.

Implementation Method 1

the guide member including an inclined surface that abuts the other in conjunction with rearward movement of the power converter during a vehicle frontal collision and thereby displaces the auxiliary machine relatively upward

Methodology Applied

Scientific EffectInclined plane: Inclined Plane

Data Source

PatentUS12534138B2Vehicle front structure

Publication Date: 2026.01.27 MAZDA MOTOR CORP

AI summary

To enhance safety of an occupant by suppressing rearward movement of an auxiliary machine during a vehicle frontal collision, a front structure of a vehicle includes an inverter arranged in a compartment in a front portion of the vehicle, and a brake booster arranged at a position that is behind the inverter and overlaps the inverter when seen in a vehicle front-rear direction. A protector is attached to a portion that is a rear end portion of the inverter and opposes the brake booster. The protector includes a guide portion having an inclined surface that abuts the brake booster in conjunction with rearward movement of the inverter and displaces the brake booster upward.