Power Electric Module Mounting Bracket for NVH and Space Optimization
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Solution Overview
Problem
In vehicles transitioning from internal combustion engines to electric vehicles, mounting the power electric module on the sub-frame is costly and may compromise durability and noise, vibration, and harshness (NVH) performance, while mounting it on the side member or upper panel results in reduced trunk space and potential separation during collisions.
Innovation Solution
A power electric module mounting structure that includes a front side member with a bulk head and mounting bracket connecting the side and upper surfaces, utilizing a connection pipe and rod system to securely attach the module, reducing its size and center of gravity distance, thereby improving NVH performance and preventing separation during collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the power electric module is mounted on the sub-frame, then the distance from the mass center is short improving durability and NVH performance, but the mounting cost increases considerably and it may compromise durability
Solution Approach 1:
The patent introduces a mounting bracket as an intermediary component that connects the power electric module to the side member. This bracket serves as a mediator that enables mounting on the side member (avoiding sub-frame complexity) while still achieving short distance from mass center (maintaining durability and NVH performance). The bracket translates the connection between two components that would otherwise be incompatible.
Solution Approach 2:
The mounting structure is segmented into multiple components: the side member, the mounting bracket with connection portions, and the power electric module. This segmentation allows each component to be optimized independently - the side member for structural integration, the bracket for connection functionality, and the module for power functions. It avoids the need for a complete sub-frame structure.
2Ease of manufacture
If the power electric module is mounted on the side member, then the mounting cost is reduced and integration is improved, but there may be a problem of separation when a vehicle crashes
Solution Approach 1:
The mounting bracket merges multiple connection functions into a single integrated component. It combines the first connection portion (connecting to side surface), second connection portion (connecting to upper surface), and bulk head (providing collision resistance) into one unified structure. This merging ensures that collision resistance is built into the mounting structure itself, not added as a separate feature.
Solution Approach 2:
The mounting bracket appears to be designed as a composite structure combining different material properties or structural characteristics in different regions. The bulk head portion is designed for collision resistance, while the connection portions are optimized for attachment. This composite approach allows the single bracket to simultaneously achieve ease of manufacture and collision resistance.
3Volume of moving object
If the power electric module is mounted on the upper panel, then the space occupation is reduced, but the distance from sub-frames increases resulting in disadvantages in durability and NVH performance
Solution Approach 1:
The patent transitions from traditional vertical mounting (on upper panel) or rear mounting (on sub-frame) to a longitudinal dimension mounting on the side member. By utilizing the side member's length in the longitudinal direction, the power electric module can be positioned closer to the front of the vehicle, reducing its distance from the mass center while still optimizing front trunk space. This dimensional shift resolves the contradiction between space occupation and durability.
4Ease of manufacture
If the power electric module is mounted on the side member, then the mounting cost is reduced, but the space for the front trunk is reduced due to large space occupation
Solution Approach 1:
The mounting bracket is designed with local quality variations - different connection portions are optimized for different functions. The first connection portion connects to the side surface, the second connection portion connects to the upper surface, and the bulk head provides structural support. This localized optimization allows the overall structure to achieve cost-effective mounting while minimizing space occupation through precise geometric design.
Data Source
AI summary
A power electric module mounting structure may include a front side member provided in a longitudinal direction of a vehicle body and including a side surface formed in an internal direction of the vehicle body and an upper surface connected to the side surface, a bulk head mounted inside the front side member, and a mounting bracket connected to the side surface and the upper surface of the front side member through the bulk head to mount a power electric module on the mounting bracket.