Vehicle Front Structure High-Voltage Component Placement

Solution Overview

Problem

In vehicle front structures with fuel cell units and high-voltage components, there is a risk of interference and damage due to impact loads, particularly when these components are placed in close proximity, leading to potential damage from collisions.

Innovation Solution

A vehicle front structure design that includes a pair of front side members, a fuel cell unit, a high-voltage component, and an impact absorber, where the high-voltage component is placed outwardly from the front side members, and the impact absorber is positioned between the fuel cell unit and the high-voltage component to absorb kinetic energy, ensuring the high-voltage component is protected by the rigidity of the side members and dash panel.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If the high-voltage component is placed inwardly from the front side member to save mounting space, then the mounting space utilization is improved, but the interference protection between fuel cell unit and high-voltage component deteriorates

Engineering Contradiction:

Improvemounting space utilizationVSAvoidinterference protection

Core Design Contradiction:

Area of stationary objectVSReliability

Solution Approach 1:

The high-voltage component is positioned in the vehicle up-down direction (vertical dimension) rather than only in the vehicle width direction (horizontal dimension). Specifically, the high-voltage component is placed above the front side member, utilizing the vertical space between the front side member and the dash panel. This dimensional transition allows the component to be mounted efficiently while maintaining sufficient horizontal separation from the fuel cell unit for impact protection.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If the high-voltage component is placed outwardly from the front side member to prevent interference, then the interference protection is improved, but the mounting space utilization deteriorates

Engineering Contradiction:

Improveinterference protectionVSAvoidmounting space utilization

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The high-voltage component is positioned in the vehicle up-down direction (vertical dimension) rather than only in the vehicle width direction (horizontal dimension). Specifically, the high-voltage component is placed above the front side member, utilizing the vertical space between the front side member and the dash panel. This dimensional transition allows the component to be mounted efficiently while maintaining sufficient horizontal separation from the fuel cell unit for impact protection.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Area of stationary object

If the fuel cell unit and high-voltage component are placed around each other to maximize space usage, then the mounting space utilization is improved, but the impact resistance deteriorates

Engineering Contradiction:

Improvemounting space utilizationVSAvoidimpact resistance

Core Design Contradiction:

Area of stationary objectVSStrength

Solution Approach 1:

The high-voltage component is positioned in the vehicle up-down direction (vertical dimension) rather than only in the vehicle width direction (horizontal dimension). Specifically, the high-voltage component is placed above the front side member, utilizing the vertical space between the front side member and the dash panel. This dimensional transition allows the component to be mounted efficiently while maintaining sufficient horizontal separation from the fuel cell unit for impact protection.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The mounting space is segmented into distinct functional zones: the fuel cell unit is positioned in the lower region bounded by front side members, while the high-voltage component is positioned in the upper region above the front side member and below the dash panel. This spatial segmentation prevents interference between components during impact while effectively utilizing the available three-dimensional mounting space.

Inventive Principle:

Principle #1Segmentation

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 restrains interference between the fuel cell unit and the high-voltage component during impact, providing stable impact absorption and protecting the high-voltage component from damage by distributing the impact energy through the impact absorber and rigid structural members.

Implementation Method 1

an impact absorber provided between the fuel cell unit and the high-voltage component... to absorb kinetic energy

Methodology Applied

Scientific EffectImpact absorption: Damping

Data Source

PatentUS10543872B2Vehicle front structure

Publication Date: 2020.01.28 TOYOTA JIDOSHA KK

AI summary

A vehicle front structure includes a pair of front side members, the front side members being respectively placed on the right side and on the left side in a vehicle width direction in a vehicle front space ahead of a vehicle cabin space in a vehicle, so as to extend in a vehicle front-rear direction. A fuel cell unit is placed in a region sectioned by the front side members in the vehicle front space. A high-voltage component is placed above the front side members, and an inner edge portion of the high-voltage component in the vehicle width direction is placed outwardly in the vehicle width direction from an inner edge portion of the front side member in the vehicle width direction.