Non-metal Duct Member Vibration Control for High-Voltage Electrical Units
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Solution Overview
Problem
Existing vehicle installation structures for high-voltage electrical apparatuses in electric vehicles face challenges in efficiently cooling these components while maintaining a compact and cost-effective design, as well as effectively managing vibrations.
Innovation Solution
A vehicle installation structure that fixes an electrical unit with a cooling structure, featuring a duct member made of non-metal material, to a vehicle frame via a bracket, where at least one high-voltage electrical apparatus is integrally fastened to the bracket with a connecting member, eliminating the need for separate vibration control components and reducing the number of individual connecting members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate connecting members are used to fasten the electrical apparatus and duct member to the bracket, then the connection reliability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple separate connecting members into a single integrated connecting member that simultaneously fastens both the electrical apparatus and the duct member to the bracket. This merging approach reduces the total number of components while maintaining secure connection reliability through the integrated design.
Solution Approach 2:
The single connecting member is designed to perform multiple functions: it fastens the electrical apparatus to the bracket, fastens the duct member to the bracket, and provides vibration resistance. This multi-functional design eliminates the need for separate components for each function, reducing device complexity while maintaining reliability.
2Device complexity
If a compact design is implemented by reducing the number of components, then the device size and manufacturing cost are reduced, but the vibration resistance may deteriorate
Solution Approach 1:
The patent merges the vibration resistance function into the single connecting member by incorporating vibration-resistant structural features directly into the connector design. This allows vibration protection to be integrated without requiring additional separate vibration control components.
Solution Approach 2:
The connecting member is designed as a composite structure that combines rigid fastening features with vibration-damping materials or structures. This composite approach allows the single component to provide both secure mechanical fastening and vibration resistance, maintaining reliability while reducing overall device complexity.
3Strength
If metal materials are used for the duct member, then the structural strength is improved, but the vibration control capability deteriorates
Solution Approach 1:
The patent employs composite material construction for the duct member, combining metal components for structural strength with non-metallic vibration-damping materials. This composite approach allows the duct member to simultaneously provide the structural integrity needed for support while incorporating vibration control capabilities through the damping materials.
Solution Approach 2:
The duct member is designed with different material properties in different regions: metal portions provide structural strength where needed, while non-metallic portions provide vibration damping where required. This localized quality approach allows the single duct member to fulfill multiple functional requirements simultaneously.
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 reduces the number of components, provides efficient cooling, and enhances vibration resistance for high-voltage electrical apparatuses in an economical and compact setup, while integrating vibration control functions into the duct member.
Implementation Method 1
a duct member that is made of a non-metal material... integrating vibration control functions into the duct member
Implementation Method 2
cooling air is introduced to an electrical unit that includes the high-voltage electrical apparatuses and the high-voltage electrical apparatuses are cooled by heat exchange with the cooling air
Data Source
AI summary
A vehicle installation structure includes a vehicle frame and an electrical unit. The electrical unit includes at least one first high-voltage electrical apparatus, a cooling structure, and a bracket. The cooling structure is to cool the at least one first high-voltage electrical apparatus. The cooling structure has a duct member made of a non-metal material. The bracket is attached to the vehicle frame. The at least one first high-voltage electrical apparatus is connected to the bracket via the duct member with a connecting member.