Battery Module Terminal Block Shielding for EMI Grounding
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Solution Overview
Problem
Existing battery modules do not effectively shield against electromagnetic noise, which can cause malfunction of electronic components, posing a safety risk, especially in vehicles with high power consumption.
Innovation Solution
A battery module design featuring a housing with a high-voltage connector that includes a terminal block surrounded by a shielding portion, a bracket with ground holes, and a connection block, where helical patterns in the ground holes ensure secure electrical connections to ground the electromagnetic noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a battery module is designed without electromagnetic shielding, then the device complexity is reduced and manufacturing is simpler, but electromagnetic noise causes malfunction of electronic components
Solution Approach 1:
The shielding portion is integrated within the terminal block structure itself, with the shielding portion surrounding the electrode and being electrically connected to the ground. This nested design embeds the shielding function within the existing connector geometry rather than adding separate external shielding components, thereby providing electromagnetic protection while maintaining structural simplicity.
Solution Approach 2:
The terminal block is designed to serve multiple functions: electrical connection through the electrode, electromagnetic shielding through the shielding portion, and ground connection through the integrated ground path. By combining these functions into a single component, the design achieves reliable electronic component protection without increasing overall device complexity.
2Object-affected harmful factors
If electromagnetic shielding is added to the battery module, then protection against electromagnetic noise is improved, but the manufacturing process becomes more difficult
Solution Approach 1:
The shielding portion is merged with the terminal block as an integrated component rather than a separate part. The terminal block includes the electrode, shielding portion, and ground connection features all combined in a single structure, which simplifies manufacturing by reducing the number of assembly steps and eliminating the need for separate shielding installation processes.
Solution Approach 2:
The shielding portion is strategically positioned only around the electrode where electromagnetic noise generation occurs, rather than enclosing the entire battery module. This localized shielding approach provides effective electromagnetic protection while minimizing material usage and simplifying the manufacturing process compared to full-enclosure shielding designs.
3Object-affected harmful factors
If a simple ground connection is used, then the device complexity is reduced, but electromagnetic noise cannot be effectively removed
Solution Approach 1:
The ground connection features are nested within the terminal block structure, with ground holes formed in the bracket and electrical connection features integrated into the terminal block body. This nested ground path design provides effective electromagnetic noise removal while maintaining a compact and simple overall structure.
Solution Approach 2:
The bracket serves as an intermediary component that provides the ground path between the terminal block and the housing. The bracket includes ground holes that establish electrical connections, mediating the ground current flow from the shielding portion through the terminal block to the housing, thereby effectively removing electromagnetic noise without requiring complex ground routing.
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 design effectively shields and removes electromagnetic noise, preventing malfunctions in electronic units and enhancing driving safety by providing a stable ground path for electromagnetic interference.
Implementation Method 1
a shielding portion formed to surround the electrode
Implementation Method 2
a helical pattern is formed in the first and second ground holes
Data Source
AI summary
A battery module is provided. The battery module includes: a housing accommodating a plurality of battery packs electrically connected to each other; and a high-voltage connector formed on the housing, wherein the high-voltage connector includes: a terminal block including an electrode through which current flows and a shielding portion formed to surround the electrode; a connection block electrically connected to the shielding portion; and a bracket interposed between the terminal block and the connection block, wherein the bracket includes a first ground hole forming an electrical connection with the connection block and a second ground hole forming an electrical connection with the housing, and a helical pattern is formed in the first and second ground holes. Accordingly, electromagnetic noise may be effectively shielded and removed.