Conductive Plastic Screen Shield for High-Voltage Power Distributors
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Solution Overview
Problem
Existing high-voltage power distributors for electric vehicles are expensive due to the use of metallic screens for electromagnetic compatibility, and there is a need for a more cost-effective solution.
Innovation Solution
A power distributor with conductors enclosed by a screen shield made from electrically conducting plastic material, featuring elastic spring contacts made from metal that provide a metal-to-metal contact, enhancing electrical conductivity and compensating for mechanical tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a metal screen shield is used in the power distributor, then electromagnetic compatibility is ensured, but manufacturing cost increases
Solution Approach 1:
The patent uses a composite structure combining electrically conducting plastic material for the screen shield body with metal spring contacts. This composite approach maintains electromagnetic shielding effectiveness while reducing manufacturing cost compared to pure metal screens, as the plastic material is cheaper to process and manufacture.
Solution Approach 2:
The patent changes the material parameter from pure metal to electrically conducting plastic, which has sufficient electrical conductivity for shielding purposes but lower cost. The addition of metal spring contacts optimizes the electrical contact parameter while keeping the overall structure cost-effective.
2Ease of manufacture
If an electrically conducting plastic screen shield is used, then manufacturing cost is reduced, but electrical conductivity may be insufficient
Solution Approach 1:
The patent employs a composite design where metal spring contacts are integrated with the electrically conducting plastic screen shield. The metal contacts provide high electrical conductivity at critical contact points, compensating for the lower conductivity of the plastic material while maintaining cost advantages.
Solution Approach 2:
Instead of making the entire screen shield from high-conductivity metal, the patent applies metal spring contacts only at specific locations where electrical contact is critical. This local quality approach ensures sufficient conductivity where needed while keeping overall manufacturing costs low.
3Reliability
If rigid contacts are used between screen shield and individual screens, then electrical contact is established, but mechanical tolerances cannot be compensated
Solution Approach 1:
The patent replaces rigid contacts with elastic spring contacts that can dynamically adapt to mechanical tolerances. The spring mechanism provides continuous contact pressure while accommodating variations in assembly dimensions, ensuring reliable electrical connection despite manufacturing tolerances.
Solution Approach 2:
The elastic spring contacts are designed beforehand to compensate for expected mechanical tolerances. The spring mechanism pre-absorbs dimensional variations through its elastic deformation, ensuring stable electrical contact without requiring extremely tight manufacturing tolerances.
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 manufacturing costs while maintaining effective electromagnetic compatibility by ensuring good electrical conductivity and mechanical stability, even under vibrations.
Implementation Method 1
The elastic spring contacts can compensate for mechanical tolerances of the components making the electrical contact
Implementation Method 2
The elastic spring contacts from metal. Most metals have good electrical conductivity
Implementation Method 3
a screen shield that contacts each individual screen of the incoming lines... The screen shield is made from electrically conducting plastic material
Data Source
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AI summary
A power distributor (200) with at least two incoming lines (101-103) and a method for manufacturing such a power distributor is suggested. Each incoming line comprises a conductor (106,107) and an individual screen (114). The conductors of the incoming lines are connected at a connection point (V1,V2), which is enclosed by a screen shield (201) that contacts each individual screen (114) of the incoming lines. The screen shield (201) is made from electrically conducting plastic material. Screen shields made from electrically conducting plastic material is easier to manufacture and less expensive than metal screen shields.