Composite Protective Element for EV EMC and Thermal Shielding
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Solution Overview
Problem
Modern electrically powered vehicles face challenges in ensuring electromagnetic compatibility (EMC) while also protecting against external impacts like stone strikes and thermal runaway in battery cells, with existing solutions often increasing vehicle weight and complexity.
Innovation Solution
A protective element comprising a shielding layer made of materials like aluminum foil, a plastic layer, and optional reinforcing layers, with contacting elements for electrical connection, designed to minimize weight and complexity while providing EMC protection and thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate protective components (EMC shielding, stone impact protection, thermal insulation) are used, then protection effectiveness is improved, but vehicle weight and complexity increase
Solution Approach 1:
The patent combines multiple protective functions (EMC shielding, stone impact protection, thermal insulation) into a single integrated protective element. The shielding layer provides EMC protection while the plastic layer with reinforcing elements provides mechanical protection against stone impacts and thermal insulation, eliminating the need for separate components for each function.
Solution Approach 2:
The protective element uses composite material construction with a shielding layer (metal or electrically conductive material) combined with a plastic layer that may include reinforcing elements. This composite structure achieves multiple protective functions simultaneously while maintaining low weight compared to traditional separate components.
2Reliability
If traditional protective components are used for EMC shielding and mechanical protection, then protection functions are achieved, but vehicle weight increases
Solution Approach 1:
The protective element uses thin shielding layers (0.05-2.0 mm thick) made of metal or electrically conductive materials combined with plastic layers. This thin-film approach provides effective EMC shielding and mechanical protection without the weight of traditional thick protective components.
Solution Approach 2:
The composite structure of shielding layer plus plastic layer with optional reinforcing elements provides both EMC protection and mechanical strength using lightweight materials, reducing overall vehicle weight compared to traditional separate protective components.
3Reliability
If shielding layer thickness is increased for better EMC protection, then EMC shielding effectiveness is improved, but production cost and material usage increase
Solution Approach 1:
The patent optimizes the shielding layer thickness to a specific range (0.05-2.0 mm) that provides sufficient EMC shielding effectiveness while minimizing material usage and production cost. This parameter optimization balances performance requirements with manufacturing economy.
Solution Approach 2:
The composite structure allows the shielding layer to be thinner because the plastic layer with reinforcing elements provides additional protective functions. This reduces the burden on the shielding layer thickness while maintaining overall protection effectiveness and reducing material costs.
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 against electromagnetic interference, protects against stone impacts and thermal runaway, and ensures electrical connectivity with minimal weight and production costs.
Implementation Method 1
The protective element comprises a shielding layer for shielding from electromagnetic radiation
Implementation Method 2
designed to minimize weight and complexity while providing EMC protection and thermal insulation
Data Source
AI summary
A protective element for arrangement on a device which emits electromagnetic radiation, wherein the device can be, for example, an at least partially electrically powered motor vehicle, the protective element comprising the following: a shielding layer for shielding against electromagnetic radiation, a plastic layer, and a contacting zone via an electrical contact can be established between the shielding layer and the device.