Vehicle Bodywork Conductive Surface for Current Dissipation
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Solution Overview
Problem
Modern vehicles with increasing electrical equipment face challenges in dissipating undesirable electric currents, particularly when using bodywork parts made of non-conductive materials, as conventional solutions like metal sheets are costly and complex to implement.
Innovation Solution
A bodywork element with a conductive surface made of electrically conductive material is integrated between internal structure elements within a non-conductive lining, allowing for the dissipation of undesirable electric currents without the need for additional metal sheets during molding, using a sheet of conductive material such as aluminum reinforced with plastic to prevent tearing and facilitate attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If bodywork parts are made of plastic or composite materials to reduce cost and weight, then manufacturing cost and weight are reduced, but electrical conductivity for dissipating unwanted currents is lost
Solution Approach 1:
The patent uses a composite structure combining non-conductive plastic bodywork with embedded conductive elements (metal sheets, conductive paints, or conductive composites) to achieve both cost reduction and electrical conductivity. The conductive elements are integrated into the plastic bodywork during molding or as separate components, creating a hybrid material system that provides both structural and electrical functions.
Solution Approach 2:
The patent applies conductive treatments or embeds conductive elements only in specific locations where electrical conductivity is needed, rather than making the entire bodywork conductive. This allows cost-effective implementation by concentrating conductive materials only where required for EMI shielding and current dissipation, while maintaining non-conductive properties in other areas.
2Reliability
If metal sheets are added during molding to provide electrical conductivity, then electrical conductivity is improved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent explores alternative conductive solutions with different material parameters and properties. Instead of relying solely on metal sheets, it considers conductive paints, conductive composites, and coated fabrics that can be applied more simply. This changes the material parameters from thick metal layers to thinner, easier-to-apply conductive layers, reducing manufacturing complexity while maintaining conductivity.
Solution Approach 2:
The patent considers using thinner, less expensive conductive materials that may be less durable than thick metal sheets but are easier and cheaper to apply. These could include conductive paints or thin coated fabrics that provide sufficient conductivity for EMI protection without the complexity of integrating thick metal sheets during molding.
3Reliability
If conventional metal braids and earth connections are used to dissipate electric currents, then electrical equipment protection is improved, but device complexity and implementation cost increase
Solution Approach 1:
The patent combines the structural bodywork function with the electrical grounding function by integrating conductive elements directly into the bodywork structure. This merges two separate systems (mechanical support and electrical dissipation) into a single integrated component, eliminating the need for separate metal braids and earth connections, thereby reducing overall device complexity.
Solution Approach 2:
The patent makes the bodywork structure itself serve multiple functions: providing mechanical support, enabling EMI shielding, and dissipating electrical currents. By making the bodywork itself conductive through embedded elements, it becomes a multi-functional component that replaces dedicated grounding systems, reducing the number of separate components needed.
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 solution effectively dissipates undesirable electric currents, reduces manufacturing costs, and simplifies the production process while maintaining protection against electromagnetic interference, even with non-conductive bodywork materials, by spreading the conductive surface between internal structure elements within the lining.
Implementation Method 1
a conductive surface of electrically conductive material is spread at a distance from the lining, so as to let the electrical energy dissipate
Data Source
AI summary
Disclosed is a bodywork part of a motor vehicle including a lining defining an internal volume intended for being closed by an outer skin, the lining consisting of an electrically non-conductive material. The bodywork element includes at least two internal structure elements arranged in the internal volume, between which a conductive surface of electrically conductive material is spread at a distance from the lining.