Interlocking Vehicle Power Module Assembly for Sealed Coolant Alignment
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Solution Overview
Problem
Existing vehicle power module assemblies face challenges in securely stacking and aligning power modules while maintaining a sealed coolant flow to manage thermal conditions effectively, often requiring external fasteners that complicate assembly and increase the risk of coolant leakage.
Innovation Solution
The vehicle power module assembly employs interlocking lock features such as loop elements and wedge elements, and flexible hook elements and slots, which secure the power modules together without external fasteners, ensuring a sealed relationship and alignment of coolant channels for efficient thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If external fasteners are used to secure power modules, then the modules can be stacked and secured, but the assembly complexity increases and the risk of coolant leakage increases
Solution Approach 1:
The locking feature and sealing feature are merged into a single integrated component that performs both functions simultaneously. The locking feature includes a locking portion that secures the modules together and a sealing portion that prevents coolant leakage, eliminating the need for separate external fasteners and gaskets.
Solution Approach 2:
The locking feature is designed to perform multiple functions: mechanical locking to secure modules, sealing to prevent leakage, and alignment to ensure proper positioning. This multi-functional design reduces the number of separate components needed in the assembly.
2Stability of the object's composition
If external fasteners are used to secure power modules, then the modules can be stacked and secured, but the manufacturing and assembly process becomes more complex
Solution Approach 1:
The locking feature and sealing feature are merged into a single integrated component that performs both functions simultaneously. The locking feature includes a locking portion that secures the modules together and a sealing portion that prevents coolant leakage, eliminating the need for separate external fasteners and gaskets.
3Reliability
If traditional stacking methods are used, then power modules can be connected, but the alignment of coolant channels becomes difficult and sealed relationship is compromised
Solution Approach 1:
The locking feature is designed with built-in alignment guides and positioning structures that automatically align the coolant channels of adjacent modules before the modules are fully secured together. This preliminary alignment action ensures proper channel registration and maintains the sealed relationship without requiring high-precision manual alignment.
Solution Approach 2:
The locking feature and sealing feature are merged into a single integrated component that performs both functions simultaneously. The locking feature includes a locking portion that secures the modules together and a sealing portion that prevents coolant leakage, eliminating the need for separate external fasteners and gaskets.
Data Source
AI summary
A vehicle power module assembly including first and second power modules is provided. The first power module may include a first lock feature extending from a lower portion of a first minor side at a first central axis. The second power module may include a second lock feature at an upper portion of a second minor side at a second central axis. The lock features may be sized for interlock with one another to secure the power modules to one another. The first lock feature may be a loop element defining a through-hole and the second lock feature may be a wedge. The through-hole may be sized for the wedge to extend therein and to interlock the first power module and the second power module to one another. The first lock feature may be a flexible hook element and the second lock feature may be a slot.