Multi-Layered Box Housing for Vehicle Power Equipment Electromagnetic Shielding

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Solution Overview

Problem

Current solutions for encapsulating batteries in electric or hybrid vehicles using aluminum casings are costly, heavy, and inefficient in shielding electromagnetic radiation, posing challenges for mass production and electromagnetic interference protection.

Innovation Solution

A multi-layered casing design featuring a plastic or composite shell with a base conductive layer of high conductivity materials like aluminum and an additional magnetic shielding layer, separated by an insulating material, which enhances electromagnetic shielding efficiency while reducing material costs and weight.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If a solid aluminum casing is used for electromagnetic shielding, then shielding efficiency is improved, but weight and production cost increase significantly

Engineering Contradiction:

Improveelectromagnetic radiation shieldingVSAvoidcasing weight

Core Design Contradiction:

Object-affected harmful factorsVSWeight of moving object

Solution Approach 1:

The patent applies composite materials by combining a plastic or composite shell with multiple conductive layers (base conductive layer and additional conductive layer) to create a hybrid structure that achieves electromagnetic shielding without the weight of solid aluminum casings

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The shielding function is segmented into multiple thin conductive layers applied on different sides of the shell, replacing the monolithic solid aluminum structure with distributed thin layers that collectively provide shielding

Inventive Principle:

Principle #1Segmentation

2Object-affected harmful factors

If a solid aluminum casing is used for electromagnetic shielding, then shielding efficiency is improved, but production cost increases

Engineering Contradiction:

Improveelectromagnetic radiation shieldingVSAvoidproduction cost

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The use of plastic or composite shells combined with thin conductive layers reduces material costs compared to solid aluminum, while the layering process enables cost-effective mass production through standardized manufacturing steps

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Dividing the shielding function into separate applyable layers allows for more efficient production processes, including potential pre-fabrication and assembly, reducing overall manufacturing complexity and cost

Inventive Principle:

Principle #1Segmentation

3Strength

If a solid aluminum casing is used, then mechanical strength is improved, but weight and cost increase

Engineering Contradiction:

Improvemechanical strengthVSAvoidcasing weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The plastic or composite shell provides the primary mechanical structure and strength, while the thin conductive layers add shielding functionality without significant weight penalty, creating a lightweight composite structure

Inventive Principle:

Principle #40Composite materials

4Weight of moving object

If thin conductive layers are used instead of solid aluminum, then weight and cost are reduced, but shielding efficiency may decrease

Engineering Contradiction:

Improvecasing weightVSAvoidelectromagnetic radiation shielding

Core Design Contradiction:

Weight of moving objectVSObject-affected harmful factors

Solution Approach 1:

The shielding function is divided into multiple thin layers (base conductive layer and additional conductive layer) applied on different sides of the shell, with each layer contributing to the overall shielding effect, achieving adequate protection without requiring thick single layers

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The plastic or composite shell acts as an intermediary between the conductive layers, providing structural support and positioning the layers optimally to maximize their shielding effectiveness while minimizing material usage

Inventive Principle:

Principle #24Intermediary (Mediator)

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 multi-layered casing provides effective electromagnetic shielding with improved mechanical resistance, lightness, and cost-effectiveness, effectively preventing electromagnetic radiation from escaping or disturbing vehicle electronics, while being suitable for large-scale production.

Implementation Method 1

electromagnetic shielding proves necessary around the accommodation space to confine the significant fields generated by the batteries and / or other electrical power components

Methodology Applied

Scientific EffectElectromagnetic shielding: Faraday Cage

Implementation Method 2

the additional conductive layer consists of a shielding material of the magnetic type... the magnetic type shielding material exhibits a relative magnetic permeability having a value greater than 100

Methodology Applied

Scientific EffectMagnetic shielding: Magnetic Field

Data Source

PatentEP2974578B1Box section housing motor vehicle power equipment forming electromagnetic screening

Publication Date: 2018.09.19 COMPAGNIE PLASTIC OMNIUM SA

Figure 1~2

AI summary

The invention relates to a box section housing motor vehicle drive electric power transmission and/or storage onboard equipment, comprising a conductive base layer extending over the entirety of a surface described by the box section, the box section comprising an additional conducting layer (20) made up of at least one conducting material and at least partially covering said conducting base layer (30).