Resin Component Cable Protection in Hybrid Vehicle PCU Mounting
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Solution Overview
Problem
Existing electric vehicle mounting structures fail to effectively protect high-voltage cables from being caught between electric equipment and other components during deformation or movement, often increasing costs and complicating the structure.
Innovation Solution
An electric equipment mounting structure that includes a resin component positioned within a closed space, such as an engine room, with high-voltage lines connected to its surface, allowing the resin component to absorb shock and protect the cables without the need for additional protective members or increased costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional protective members are provided to protect high-voltage cables from being caught between electric equipment and other components, then cable protection is improved, but device complexity and costs increase
Solution Approach 1:
The resin component serves dual purposes: it functions as a structural element of the closed space and simultaneously acts as a protective cushion for the high-voltage cable. The resin component's inherent deformability allows it to absorb collision forces without requiring separate protective structures, thus achieving cable protection through self-service of existing components
Solution Approach 2:
The resin component is designed to perform multiple functions: it forms part of the closed space structure, provides electrical insulation, and serves as a shock-absorbing protective element for the cable. By making the resin component multi-functional, the patent eliminates the need for additional dedicated protective members
2Reliability
If additional protective members are provided to protect high-voltage cables, then cable protection is improved, but manufacturing costs increase
Solution Approach 1:
The resin component protects the cable through its own structural properties without requiring separate protective members. This self-service approach eliminates additional manufacturing steps and material costs associated with dedicated cable protection structures
Solution Approach 2:
The patent merges the cable protection function with the existing resin component structure. Instead of adding separate protective elements, the protection function is integrated into the resin component itself, reducing total part count and manufacturing complexity
3Volume of moving object
If the resin component is positioned close to the electric equipment, then space utilization is improved, but cable protection effectiveness decreases
Solution Approach 1:
The resin component is strategically positioned at specific locations where cable vulnerability occurs during deformation. Rather than uniformly distributing the component, it is placed locally at critical zones to provide targeted protection while maintaining efficient space utilization
4Strength
If rigid structures are used to protect cables, then protection strength is improved, but shock absorption capability decreases
Solution Approach 1:
The patent changes the mechanical parameters of the protecting structure by using a resin component with specific viscoelastic properties. This material exhibits both strength and deformability, allowing it to provide protection while absorbing shock through controlled deformation rather than rigid resistance
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 protects high-voltage lines from damage during deformation or movement, maintaining structural simplicity and cost-effectiveness.
Implementation Method 1
the resin component can deform to absorb the shock
Implementation Method 2
the resin component can deform to absorb the shock
Data Source
Figure 1
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AI summary
An electric equipment mounting structure includes: a PCU (700) mounted inside an engine room (2) of a hybrid vehicle (1); an air cleaner (800) mounted inside the engine room (2) of the hybrid vehicle (1) with a distance between the PCU (700); and cables (900A, 900B, 900C) connected to a surface, facing the air cleaner (800), of the PCU (700).