Conductive Polymer Charger EMI Shield and Thermal Management
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Solution Overview
Problem
Charger assemblies for electric and hybrid vehicles face challenges with high heat output and electromagnetic interference (EMI) due to the conversion of alternating current to direct current, which affects durability, weight, cost, and efficiency.
Innovation Solution
A charger assembly with a conductive polymeric housing and heat transfer ducts using thermally conductive heat sinks and a dual-layer EMI shield assembly made from conductive polymers with metallic coatings to manage heat and EMI effectively, reducing weight and complexity while enhancing shielding and thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional metal housing and EMI shielding materials are used, then EMI shielding effectiveness is improved, but weight and manufacturing cost increase
Solution Approach 1:
The patent uses conductive polymer composite materials that combine polymer matrices with conductive fillers (such as carbon fibers, metal particles, or conductive polymers) to achieve both EMI shielding effectiveness and weight reduction. These composite materials provide the necessary electrical conductivity for EMI shielding while being significantly lighter than traditional metal shielding materials.
Solution Approach 2:
The patent modifies the electrical conductivity parameter of the housing material by incorporating conductive fillers into the polymer matrix. By adjusting the concentration and distribution of conductive particles, the material achieves adequate EMI shielding performance while maintaining low weight, thus changing the material properties to resolve the contradiction between shielding effectiveness and weight.
2Weight of moving object
If conductive polymer composite materials are used for housing and EMI shielding, then weight and manufacturing cost are reduced, but EMI shielding effectiveness may be compromised
Solution Approach 1:
The patent employs conductive polymer composite materials that combine polymer matrices with conductive fillers (such as carbon fibers, metal particles, or conductive polymers) to achieve both EMI shielding effectiveness and weight reduction. These composite materials provide the necessary electrical conductivity for EMI shielding while being significantly lighter than traditional metal shielding materials.
Solution Approach 2:
The patent modifies the electrical conductivity parameter of the housing material by incorporating conductive fillers into the polymer matrix. By adjusting the concentration and distribution of conductive particles, the material achieves adequate EMI shielding performance while maintaining low weight, thus changing the material properties to resolve the contradiction between shielding effectiveness and weight.
3Ease of operation
If AC to DC conversion is performed in the charger assembly, then charging functionality is enabled, but heat generation and EMI increase
Solution Approach 1:
The patent extracts the heat generation problem from the charging system by implementing dedicated heat management components. Heat sinks are positioned adjacent to power conversion components to extract heat away from the main charging circuitry, and thermal management systems are integrated to dissipate heat efficiently, thereby separating the charging functionality from its thermal byproduct.
Solution Approach 2:
The patent introduces thermal interface materials and heat transfer media as intermediaries between power conversion components and heat sinks. These intermediary materials facilitate efficient heat transfer from the AC-DC conversion components to the cooling system, enabling effective thermal management without compromising charging performance.
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 transfers heat away from critical components, reduces weight and manufacturing costs, and provides comprehensive EMI shielding across a wide frequency range, enhancing the reliability and efficiency of the charger assembly.
Implementation Method 1
heat transfer ducts using thermally conductive heat sinks
Implementation Method 2
thermally conductive heat sinks
Implementation Method 3
dual-layer EMI shield assembly made from conductive polymers with metallic coatings
Data Source
AI summary
An electromagnetic interference shield assembly is provided with a first housing formed of a first conductive polymer. The first housing has a cavity sized to receive an electronic sub-assembly therein. A second housing is formed of a second conductive polymer. The second housing has a cavity sized to receive the first housing therein.