Battery Header Shield Structure for Lightweight EMI Grounding
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Solution Overview
Problem
Existing electromagnetic shields in electric vehicles are heavy due to metal materials and prone to corrosion, adding weight and interfering with external devices.
Innovation Solution
A battery header with a polymeric body and a metal frame featuring an electromagnetic shield portion that dissipates electromagnetic radiation to an electrical ground, reducing weight and interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If metal material is used for electromagnetic shield, then electromagnetic radiation shielding is effective, but weight increases significantly
Solution Approach 1:
The patent uses a composite structure combining polymeric material and metal material in the connector plate. The polymeric portion provides structural support while the metal portion provides electromagnetic shielding, achieving effective shielding with reduced weight compared to pure metal shields.
Solution Approach 2:
The connector plate applies metal material only in specific regions where electromagnetic shielding is needed, rather than using metal throughout the entire structure. This localized application of metal reduces overall weight while maintaining shielding effectiveness in critical areas.
2Object-affected harmful factors
If metal material is used for electromagnetic shield, then shielding performance is achieved, but corrosion resistance deteriorates
Solution Approach 1:
The connector plate combines polymeric material (which is naturally corrosion-resistant) with metal material (which provides shielding). The polymer portion protects against corrosion while the metal portion provides electromagnetic shielding, achieving both goals simultaneously.
Solution Approach 2:
The design applies metal material only in localized regions where electromagnetic shielding is required, minimizing the exposed metal surface area that could be subject to corrosion. The majority of the connector plate structure uses corrosion-resistant polymeric material.
3Object-affected harmful factors
If continuous metal shield is used, then electromagnetic radiation is effectively blocked, but device complexity increases
Solution Approach 1:
The connector plate is divided into distinct polymeric and metal portions, with the metal portion forming a continuous shield only where needed for electromagnetic radiation blocking. This segmentation allows effective shielding in critical areas while simplifying the overall structure compared to a fully continuous metal shield.
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
The solution effectively shields electromagnetic radiation while minimizing weight and preventing corrosion, enhancing vehicle efficiency and operation.
Implementation Method 1
the electromagnetic shield portion is configured to dissipate electromagnetic radiation from the electrically conductive object
Data Source
AI summary
A battery component includes a header body and a frame secured to the header body. The frame includes an electromagnetic shield portion. The electromagnetic shield portion defines at least one electrical connection port. The electrical connection port is configured to receive an electrically conductive object. The electromagnetic shield portion is configured to dissipate electromagnetic radiation from the electrically conductive object.