Transfer Case Protective Plate for Hybrid Collision Loads
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Solution Overview
Problem
Hybrid vehicles experience structural failure of the transfer case during collisions, leading to the formation of sharp edges that can damage high-voltage components and cables due to increased mass and forces during impacts.
Innovation Solution
A protective plate is attached to the transfer case, formed of a rigid metal material with a planar section and flange, maintaining structural integrity by preventing the housing from breaking apart and minimizing contact with cross-bar members to avoid cable damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If hybrid vehicles include both ICE drivetrain and battery-powered drivetrain to provide combined power, then power and versatility are improved, but weight increases leading to greater collision forces that can cause transfer case structural failure
Solution Approach 1:
A protective plate is introduced as an intermediary component between the transfer case and high-voltage components. This plate absorbs and distributes collision forces, preventing the transfer case housing from cracking and thereby protecting the housing structural integrity during impact events
2Strength
If transfer case housing cracks during collision, then structural failure occurs, but this creates sharp edges that can sever high-voltage cables
Solution Approach 1:
The protective plate is pre-installed on the transfer case housing before collision occurs. This preliminary protective measure ensures that when collision forces are applied, the housing is already reinforced and less likely to crack, preventing the formation of sharp edges that could damage high-voltage cables
3Reliability
If protective plate is added to maintain housing integrity, then structural integrity is improved, but device complexity increases
Solution Approach 1:
Instead of reinforcing the entire transfer case housing, a localized protective plate is applied only to the specific area where structural failure is most likely to occur during collision. This targeted approach maintains housing integrity where needed while minimizing the addition of components and complexity
Data Source
AI summary
A vehicle that includes a propulsion system configured to drive at least one wheel of the vehicle; a high-voltage component electrically connected to the propulsion system by a high-voltage cable; a transfer case having a housing connected to the propulsion system and positioned between the propulsion system and the high-voltage component; a drive shaft connected to the transfer case; and a protective plate fixed to the housing between the transfer case and the high-voltage component; wherein in the event of the vehicle experiencing a collision event that transfers a force of the collision through the drive shaft to the transfer case that is sufficient to crack the housing, the protective plate is configured to maintain structural integrity of the housing of the transfer case.