Conductive Plastic Housing for High Voltage Electromagnetic Screening
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Solution Overview
Problem
Conventional metal housings for high voltage components in motor vehicles are heavy, expensive, difficult to manufacture, and require predetermined installation locations, failing to meet the need for lightweight, cost-effective, and easily customizable solutions that also provide electromagnetic screening and protection.
Innovation Solution
A conductive plastic housing with metallic particles is used, featuring support elements and adaptable shape via injection molding, allowing for precise configuration and reduced weight, while maintaining mechanical stability and protection standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal housing is used for high voltage components, then electromagnetic screening and contact protection are ensured, but weight and manufacturing cost increase significantly
Solution Approach 1:
The housing uses a composite structure combining non-conductive material (polymer) with conductive coating (metal layer). This composite approach provides electromagnetic screening functionality while significantly reducing weight compared to solid metal housings. The polymer base structure weighs much less than metal, and the thin conductive coating layer restores the necessary electrical conductivity for screening without adding substantial weight.
2Reliability
If metal housing is used for high voltage components, then protective function is ensured, but manufacturing complexity and cost increase
Solution Approach 1:
The housing combines polymer material with metal coating in a composite structure that is easier to manufacture than solid metal housings. The polymer can be molded into complex shapes using standard plastic molding techniques, and the conductive metal layer is applied through established coating processes, resulting in lower manufacturing complexity and cost compared to machining or forming solid metal housings.
Solution Approach 2:
The invention changes the material parameter from solid metal to a layered composite structure. This parameter change enables the use of lower-cost manufacturing processes such as plastic molding followed by coating, rather than requiring expensive metal forming and machining operations, thereby improving ease of manufacture while maintaining protective functionality.
3Ease of manufacture
If standardized housing shape is used, then manufacturing is simplified, but adaptability to different installation locations is reduced
Solution Approach 1:
The housing design incorporates adaptable mounting features and configurable opening arrangements that allow the same basic housing structure to be adapted to different installation locations and spatial configurations. The dynamic aspect is achieved through adjustable mounting brackets, reconfigurable cable access points, and flexible installation orientations, enabling one standardized housing design to serve multiple installation scenarios.
Solution Approach 2:
The housing is designed with universal mounting capabilities and configurable features that allow it to be installed in various locations and orientations within the vehicle. The standardized housing shape serves multiple functions: it provides structural containment, allows for different mounting configurations, accommodates various cable routing options, and can be installed in multiple spatial arrangements, thereby achieving versatility without requiring multiple specialized housing designs.
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 results in a housing that is lighter, less expensive, and easier to manufacture, with improved adaptability and performance in meeting mechanical, electrical, and protective requirements, including electromagnetic screening and IP67 protection.
Implementation Method 1
the housing is composed of plastic material which through the addition of metallic particles is rendered electrically conductive
Data Source
AI summary
An arrangement for high voltage components located in a motor vehicle, which has a housing for receiving the high voltage components, is completely lockable, conductive and suitable for electromagnetically screening the high voltage components. The housing has openings for electromagnetically compatibly connecting electrical lines to the high voltage components. The housing consists of plastic material which has been rendered electrically conductive by the addition of metallic particles, and has at least on one of its walls at least one support element for the same. The housing is manufactured of the plastic material filled with metallic particles by injection molding, in the shape being adapted to the spatial configurations of the location of mounting in the motor vehicle.