Conductive Composite Bulkhead for High Voltage Electrical Center
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Solution Overview
Problem
Existing battery pack housings face challenges in maintaining electromagnetic shielding effectiveness while allowing shielded cables to pass through, as conventional connector assemblies can compromise the shielding when using threaded fasteners and separate components.
Innovation Solution
A high voltage electrical center with a bulkhead formed from conductive composite material, featuring integrally formed connector shrouds and a conductive electromagnetic shield, reduces the number of components and assembly time by integrating shielding within the housing, eliminating the need for separate cables and maintaining effective EMI shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If threaded fasteners and separate components are used for connector assemblies, then electrical connections can be established, but electromagnetic shielding effectiveness is compromised
Solution Approach 1:
The bulkhead integrates multiple functions into a single component: it provides structural support, creates sealed apertures for cable passage, and maintains electromagnetic shielding continuity. The connector shrouds are formed as integral parts of the bulkhead, eliminating separate fasteners and components while preserving both electrical connectivity and EMI shielding effectiveness.
Solution Approach 2:
The bulkhead is constructed from composite material combining non-conductive structural material with conductive shielding material. This allows the bulkhead to simultaneously provide mechanical strength for structural support and electromagnetic shielding continuity, resolving the contradiction between assembly simplicity and shielding effectiveness.
2Productivity
If multiple separate components are used in connector assemblies, then electrical connections can be made, but assembly time increases
Solution Approach 1:
The bulkhead consolidates multiple discrete components (structural support elements, aperture seals, connector shrouds, and shielding elements) into a single integrated component. This reduction in component count directly decreases assembly time and complexity while maintaining all necessary electrical and electromagnetic functions.
3Adaptability or versatility
If apertures are created in housing walls for cable passage, then electrical connections are enabled, but shielding effectiveness is reduced
Solution Approach 1:
The bulkhead applies different material properties to different regions: non-conductive material provides structural support and aperture formation for cable passage, while conductive material provides electromagnetic shielding. This local differentiation allows simultaneous achievement of cable accessibility and EMI shielding continuity.
Solution Approach 2:
The composite construction of the bulkhead enables regions with different electrical properties within a single component, allowing apertures for cable passage while maintaining continuous electromagnetic shielding through conductive pathways integrated into the bulkhead structure.
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 reduces component complexity, assembly time, and ensures effective electromagnetic shielding while providing secure and sealed connections for high voltage electrical systems in electric vehicles, enhancing the overall efficiency and reliability of battery pack assemblies.
Implementation Method 1
The composite conductive material contains electrically conductive fibers within a dielectric matrix material
Data Source
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AI summary
An electrical assembly (10), such as a high voltage electrical center that controls the flow of electricity between a battery pack and the propulsion system of an electric or hybrid electric vehicle. The assembly (10) includes a plurality of electrical connectors (14) configured to receive and mate with a plurality of corresponding mating connectors and a housing containing a plurality of electrical devices interconnected to the plurality of electrical connectors (14). The housing includes a bulkhead (12) defining a plurality of connector shrouds that axially surrounds each connector in the plurality of electrical connectors (14). Each connector shroud is configured to receive a connector body of a corresponding mating connector. The plurality of connector shrouds is integral to the bulkhead (12). The bulkhead (12), and thereby the shrouds, may be formed of a composite conductive material containing electrically conductive fibers within a dielectric matrix.